By Brad Anderson, Joinery Specialist
Earlier this year I visited four joinery factories across northern Italy as part of a Stirling Machinery tour. From compact workshops with ten staff to large operations of over one hundred, each factory had one thing in common: strategic use of automation to drive efficiency, accuracy, and output. Here is what I observed, and what it means for the future of joinery in Australia and New Zealand.
In Brief
- Italian factories use targeted automation for faster, more precise joinery manufacturing.
- Component machining up to 50% faster, 99% hardware placement accuracy.
- Workers focus on quality and assembly, not repetitive tasks.
- Clean, calm, high-output environments with fewer bottlenecks.
- Modular automation can lift productivity 50–60% with only ~25% extra investment.
Joinery at scale: efficient, precise, and fully finished
Across all sites, the main products were European-style timber windows and doors, primarily tilt-turn and sliding types. One factory even produced striking full-glass fixed designs with minimal framing and concealed sashes.
Despite their size differences, every factory operated with impressive efficiency. Timely material deliveries reduced inventory management, and each product left fully assembled and finished with oiling and coatings applied.
Where automation delivered the most value
Automation was embedded throughout the entire production process, from loading and unloading optimising docking saws to infeed areas of machining cells and full machine to machine lines. Each factory took a thoughtful approach to automating the right tasks:
- Repetitive processes like docking, sanding, and small-part handling were fully automated.
- CNC machines handled precision drilling and hardware fitting with minimal rework.
- Small, detailed components were machined without manual repositioning, including moulders processing lengths as short as 100 to 300 millimetres, even when single-loaded.
- Barcode scanning automated routing through sanding and brushing lines.
- Automated material movement between machines reduced physical handling and saved time.
- One factory even used a small robot to sort and fit dowels before glue-up.
How much faster is production with automation?
While the overall production time for a complete frame was only around 15 percent faster, individual components such as stiles or sashes were machined up to 50 percent faster. Each day’s production was carefully scheduled and optimised to focus on a single component type at a time, for example running only stiles in the morning before switching to full frames in the afternoon.
This approach significantly reduced rehandling and allowed machine staff to maintain a consistent workflow. By using stacked tooling and avoiding frequent tool changes, factories increased machining efficiency with minimal downtime.
How consistent and precise is automated production?
With less manual setup, rework and trimming were minimal by the time parts reached assembly and glue-up. Machines accurately cut and drilled 99 percent of hardware locations, producing parts to exact specifications. Assembly teams had full confidence in the consistency and precision of the process.
Automated machines + people = quality outcomes
Despite high automation, every machine had an operator or supervisor. Operators did more than just push buttons; they took responsibility for quality in their area. With repetitive tasks automated, staff focused on inspections, minor repairs, and assembly—tasks often missed in manual workflows. This approach fostered ownership, craftsmanship, and pride in both components and finished products. Automation did not replace these qualities; it enhanced them. Factories were clean, highly organised, and efficient. Materials were clearly stored for smooth workflow, and machines ran continuously from 6 a.m. to 4 p.m. Yet, the atmosphere was calm and positive, with no rush despite high output. Productivity per staff member was exceptionally high.
Machines used in joinery manufacturing
We saw a range of machines in use, including docking saws from Salvador and traditional joinery moulders like Stirling’s C and E series. CNC machines played a central role, with both main processing units and smaller Comec machines forming the core of each machining cell.
These systems used barcode scanners on the stile ends to automatically feed the sander, adjust for the outer edges, and, if needed, guide the sash or door onto a brushing machine like the Sarmax.
Finishing was also automated, with infeed systems and coating lines that could switch between different finishes. Staff were responsible for hanging and unloading panels.
The opportunity for Australia and New Zealand
Many local joinery businesses rely heavily on a single CNC machine, creating bottlenecks as demand increases and skilled labour becomes harder to find. Today, automation is more affordable and accessible than ever.
Rather than relying on one complex machine to do everything adequately, breaking down the process and investing in purpose-built machines for high-skill or time-consuming tasks can dramatically improve throughput and accuracy.
Customers have reported productivity gains of 50 to 60 percent by choosing the right machine for the job. For local joinery shops, this level of automation allows them to:
- Reduce reliance on highly skilled staff for every process
- Lower overall labour costs
- Improve consistency and precision
- Create cleaner, more efficient production environments
Production can often be completed with 30 to 40 percent fewer staff for only 25 percent more investment than a traditional CNC setup.
How automation will shape the Australian timber industry
Timber joinery remains a vital part of Australia’s construction sector, especially as green building practices and higher energy efficiency standards increase demand for quality timber products.
At the same time, fewer young tradespeople are entering the industry, creating a growing skills gap. This makes it essential to transfer specialised skills into machinery and tooling. Automation enables the industry to focus skilled workers on high-value tasks like assembly and quality control, supporting sustainable growth despite labour shortages.
Brad’s takeaways
- Most eye-opening sight: A production line completing five full frames, including all hardware machining, during lunch break, followed by rapid minor repairs and immediate assembly.
- Top automation pick: Automated docking to moulder and sander, which delivered major gains in staff efficiency, material yield, and repeatable results.
Stirling Machinery’s role: a practical approach
We’re not here to sell a full factory overhaul. Instead, we help customers identify specific bottlenecks in their workflow and deliver targeted automation solutions that:
- Handle repetitive or high-precision tasks
- Reduce reliance on hard-to-find skilled staff
- Fit seamlessly into existing production setups
We partner closely with each customer to build tailored systems that do one job exceptionally well, with minimal input and maximum return.
Ready to take the next step?
If you are considering automation, my advice is to begin by reviewing your current production process. Identify the areas that slow you down or rely heavily on skilled staff.
That is where we can help. At Stirling Machinery, we support joinery manufacturers with practical automation solutions that improve workflow, reduce manual input, and increase consistency.
Get in touch with Stirling Machinery and let us help you build a more efficient, future-ready joinery operation.
About the author
This article was written by Brad Anderson, Joinery Specialist at Stirling Machinery. Brad works closely with joinery businesses to identify practical, effective automation solutions.
