Piece Labels

The argument for printing and placing labels on cut pieces is simple, “The time saved not having to figure out where the piece goes offsets of the cost to print and apply the labels.” Piece labels are most often used by truss fabricators that look for every possible way to eliminate delays in truss production.

Because the labels need to be in the same order as the pieces coming off of the saw, piece labels are created by first running the saw work through a batch cutting program. The program orders the pieces and then creates a “label file” with the piece sequence and the other information needed to create the label (the truss and piece ID, the geometry of the piece, the geometry of the truss and possibly more information.)

The label file is then loaded into a piece labeling printing program that uses the information to print a customized label for each piece. Unlike truss labels, the piece labels only need to be “tough enough” to make it from the saw to the table. Some fabricators like to have a label on each piece, other prefer “one label for every 10 pieces,” and still others believe that “one label for each unique piece” is sufficient.

If you have a lineal saw, this doesn’t work as smoothly. Since pieces are re-ordered by the lineal saw software, the best you can do is print the labels and ask the lineal saw catcher to match the label to the correct piece as it is cut.

If you decide on printing both truss and piece labels, should you plan on using the same printer for both? Although that seems like a logical approach, it may be better to have two printers. Almost certainly the truss labels will need to be more robust (and expensive) than the pieces labels, and dedicating a printer to a single kind of label means there is no need to switch “back and forth” between label types.

Although printing the labels right at the saw seems logical, many prefer to keep the label printers in the office and pre-print them as needed. Office-based printers do not need to withstand the harsher environment of the plant. Once source for labels is 

Labeling Solutions

Above are two examples of piece labels. In the first example we see graphical images of both the piece and the truss. Although it may be hard to see in this example, the piece is “highlighted” in the truss, so as to make clear exactly where this piece goes. This plant also identifies how many unique pieces are in the batch.

In the second example, the plant prints one label for each piece ID – whether it is one piece or one hundred. In this example we also see the sawyer’s name displayed – perhaps helping reinforce the feeling of accountability.

Truss Labels

Truss labels clearly identify the truss for the end user in the field, and provide contact information in case someone wants to know, "Whose truss is this?" Truss labels are printed on either rugged paper or a tough plastic and attached to every truss.

Trusses have always been “labeled,” more times than not by the stacker using a Magic Marker writing the truss ID on the 1½ " edge. Contact information can be added through use of a rubber stamp applied to the 3½ " face. Why go to the extra expense of printing and attaching a label?
"Labelers" feel that they are presenting a professional impression. Labels allow for the truss ID and contact information to always be the consistently displayed, not subject to "who is doing the marking" and weather conditions. It might only take one job site visit prompted by unreadable truss marks to get a company started making truss labels.

Although you can use a standard laser printer with some heavy stock paper, the "standard" way to create truss labels is to use a dedicated, industrial thermal printer and a roll or fan-folded stack of labels specifically designed for use with that that printer. Industrial printers are fast and have no problems with ink smearing or running. Among the thermal printers, the most often seen in the Northeast are the CL408e and CL412e printers from Sato. The "408" model works fine for most people. The "412" printer has better resolution and is a good choice, especially if you'd like to include graphics, like a logo, on the label and costs about $1,500. Don't skimp on extra memory if it's offered, it can speed up printing considerably. The Zebra S4M is also popular, and runs about $800. Datamax is another option.

The cost of printing labels includes the labels themselves, and an ink transfer strip. As labels are fed into the printer, the ink transfer strip (on a roll like packing tape) gets used up in the printing process. All told, a reasonable estimate for overall material costs are about 3 to 5 cents per label. One component manufacturer that sells $5-7 million in trusses a year calculates that he prints 66,000 labels at a cost of about $2,800 per year.
The choices for labels are many, and probably the best plan is to contact a high quality label supplier who can ask the right questions and find the best solution for you. You might ask about options for special colors and pre-printed backs. Dasko and Workflow One are two such label suppliers.

Labels are either "unsticky" and attached under a plate, or "sticky" and wrapped around a chord with the ends overlapping so the label is actually attached to itself as well as sticking to the wood. "Unsticky" labels (4” x 6" is common) are either made of paper or a tough plastic. The "wraparound" style is usually made of paper.

Label printers come with Windows drivers, just like any other business printer, that needs to be installed on the computer that will be using the printer. In MiTek's software suite, truss labels are printed using the custom report engine in the business management (MBA) software, that can be customized to look like most anything you'd like. Since MBA is also used to create the production groups, it's an easy process to print only the labels you need for a particular production group, put a rubber band around the stack, and then hand the labels to the production guys with the other paperwork.

I’d like to hear your thoughts about the value, or lack of value, in using printed labels.

Roof Truss Safety

MiTek has a couple of safety videos, built around the equipment we sell. One video is on saw safety, the other on truss production. Both are short (around 10 minutes) and are a great way to begin a safety meeting. I’ve taken some of the highlights from the truss production video and incorporated them into this article.

Restricted Zone

One of the best concepts of the Roof Truss Safety video is the concept of the Restricted Zone (also sometimes called the Safety Zone.) This is the area in and around the tables and conveyors, and extends to “far enough away from the production area such that no object (gantry head or truss) could possibly touch it." This is seen in yellow in the picture below. The Restricted Zone idea is a helpful concept for building awareness among plant workers. Whereas it is difficult for anyone to remember a long list of “do’s and don’ts, if the area defined as the Restricted Zone is clear in everyone's mind, it is easier to reinforce the basic concept – “Think when you enter this zone, you must be keely aware of what’s going on around you.”

Rules for the Restricted Zone

The video suggests everyone must be out of the Restricted Zone whenever equipment or product is moving. Note that the conveyors are just as much 'in the Zone' as the tables are. No one is to be on, between or under the equipment while it is moving. Further, the gantry operator is responsible for making sure his entire crew is out of the Zone before starting the gantry head. Each member of the crew is just as responsible for notifying the rest of the crew, particularly the gantry head operator, when entering the Zone. Awareness of the Restricted Zone can be reinforced if people use the term enough. Teaching the crew to call out to the lead person, "Entering the Restricted Zone!" when they are, in fact, entering it, is one way to do it. People are important, but care should also be taken that no equipment, such as carts or building materials should be within the Zone prior to machinery operation.

Other Important Safety Reminders 

Never get your hand, limb, hair, or clothing near the gantry head or turning roller

Never use a piece of equipment for a purpose for which it was not designed

Equipment should not sit in or be surrounded by standing water

Never wear loose clothing, dangling necklaces, or large jewelry or permit long, flowing hair when operating or maintaining any equipment

Always of activate the emergency stop (the "estop") before working on a piece of equipment

            A Purpose for Which It Was Not Designed

            One example of a "purpose for which it was not designed" was the practice of hand feeding small trusses, such as jacks, into finish rollers. The potential for harm seems obvious enough. If this is ever done at your plant, consider at  least training the crew to use a board to push the truss forward, rather than holding the truss with their hands in order to feed it into the roller.