Facing challenges in labor availability and limited throughput, S&B Pallet needed a sustainable solution that could streamline operations while controlling costs. Turning to Alliance Automation, we integrated their Robotic Pallet Dismantler and Urban Sawmill into our facility. This case study explores how these advanced solutions addressed our operational challenges, enhanced efficiency, and positioned us for long-term success.

The Situation
The problem that we were facing was of course a labor shortage, it has been tough getting folks in here to run bandsaws, build pallets, and to package lumber. We also could not get enough volume through our current equipment. The combination of a restrictive throughput on material volume and not enough labor resources, is what started us looking for a better solution. The solution that we evaluated was getting more bandsaws, that would require even more labor that we didn’t have access to, and we would eventually fill our current facility. This was, in our minds, a temporary answer. No matter how much equipment we would purchase, this answer would only get us through the next 6 to 8 months before having to start the process over again. It became this massive financial discussion with all the equipment we needed, and it was not going to solve the problem for the long term. Once we were introduced to Alliance Automation, we knew the answer was a next level solution, automation.

Starting the process
When researching to understand the situation, the prioritized problem was increasing throughput—we needed to process more pallets through the saws without hiring many more employees. This research led us to the solution of needing two more bandsaws, which would alleviate the immediate problem but not solve it long-term.  Some years back, Alliance Automation showcased their Robotic Pallet Dismantler during plant tours at NWPCA. I was heavily involved within the organization, serving as a board member for 17 years and as past president. Additionally, I served on the board of the WPA for many years and held the position of past president. I have spoken to many industry peers who were facing similar challenges. My thoughts kept returning to the plant tours, thinking that the Robotic Pallet Dismantler was the answer to our problem. I started seeking out others in the industry who had implemented the Robotic Pallet Dismantler and talked to them. Fellow pallet company owners and business associates convinced me because of their positive experiences, not only with increased productivity and efficiency but also with how fantastic Alliance Automation was to work with. When I talked to Alliance, I found their approach straightforward and relatable to my business. The positive feedback from trusted colleagues, combined with my 30 years in the business, made the decision easy.

The Solution
Alliance Automation played a crucial role in resolving our challenges by closely collaborating with my team on the layout, providing valuable suggestions, and offering exceptional support throughout the implementation process. Their deep understanding of our business and hands-on assistance during and after installing the Robotic Pallet Dismantler and Urban Sawmill were pivotal. Automation significantly increased our volume, reduced labor costs, and lowered our unit cost per piece from over $0.13 to under $0.07 on average, sometimes even hitting $0.05. This cost savings allowed us to operate more efficiently and effectively, processing around 40,000 units of lumber per day. As a result, we no longer need to wholesale to other pallet companies. By integrating the Robotic Pallet Dismantler and the Urban Sawmill not only have we increased internal volume to build more pallets but also improve inventory control. Looking ahead, we plan to add a second Robotic Pallet Dismantler and explore the benefits of the PALLETAI solution to further enhance our operations.

Outcome Highlights
Space constraints and financing were initial obstacles in adopting Alliance Automation’s Robotic Pallet Dismantler and Urban Sawmill. However, once we resolved the layout issues and secured financing, implementation proceeded smoothly. The investment is paying off ahead of schedule, targeted at a year earlier than expected. The decision-making process was collaborative, involving extensive research and site visits by our team. Initially, there was apprehension about managing the new technology, but Alliance’s support during and after installation quickly built our team’s confidence. Automation has also diversified our workforce, with women excelling as operators, outperforming their male counterparts, and reducing the need for heavy lifting. This has broadened our hiring opportunities and improved operational efficiency.