Bridging the Gap: How Automation Is Solving the Manufacturing Workforce Crisis
The manufacturing industry is facing a critical inflection point. With over 1.9 million jobs projected to go unfilled by 2033 due to a widening skills gap and an aging workforce in the U.S. alone, companies are struggling to maintain productivity and meet growing demand (NAM). But this shortage is not just a numbers game. It’s become a threat to productivity, innovation, and long-term competitiveness.
Automation offers a compelling solution: it reduces dependency on manual labor, enhances product quality, and enables scalable growth. Manual processes are physically demanding and prone to error, while the complexity of modern systems demands a level of consistency that the limited labor force alone struggles to maintain.
The Workforce Shortage
This is no longer a future concern but a present-day crisis. While the COVID-19 pandemic accelerated the loss of over 1.4 million manufacturing jobs just in the U.S., the industry is still struggling to attract and retain skilled workers, even with hiring and in-person work resuming (US Census Bureau).
Several factors contribute to this growing gap:
Aging Workforce: Many experienced workers are retiring, and younger generations are not entering the trade at the same rate.
Perception Problem: Manufacturing is often viewed as physically demanding and low-tech, deterring younger generations.
Technological Evolution: As automation and advanced production methods become standard, the demand for digitally skilled workers continues to increase.
Training Deficit: Many companies lack structured training programs to upskill existing employees or onboard new ones effectively.
Companies unable to fill critical roles risk falling behind in productivity, innovation, and competitiveness. In fact, according to a survey done by the National Association of Manufacturers (NAM), 60% of manufacturers noted that attracting new talent and retaining employees are among the top challenges.
In fenestration manufacturing, where precision and ergonomics are key, the shortage is even more pronounced. Manual tasks like screen assembly and frame handling are physically demanding and require specialized skills—skills that are increasingly hard to find. The result is a bottleneck in production and a growing need for solutions that reduce reliance on manual labor.
Automation: From Luxury to Necessity
Automation is a necessary strategy to keep up with the evolving landscape, address the labor shortage, and attract younger generations of the workforce. For fenestration, automation offers a way to streamline repetitive tasks, reduce errors, and maintain consistent quality.
“The window manufacturer doesn’t have a choice. They don’t have a choice in today’s day and age to not integrate this level of industrial automation into what they’re doing, and if they don’t do it, they’re going to be surpassed by the competition,” says President of Haffner Machinery North America, Stephen Kucer.
Key factors to consider when thinking about integrating automation include:
Bridging the labor-skills gap
Reducing safety risks like accidents and injuries
Ensuring quality control with standardized operations
Optimizing production costs while improving efficiencies
Haffner Machinery’s AUTOSCREEN™ product line is a prime example of this shift. The three-part cell automates screen assembly from start to finish with just one operator per step. This system alone can produce 1,000 screens per shift, reducing the strain on hiring while increasing throughput.
By integrating automation into their workflows, manufacturers can scale production without compromising quality.
Ready to automate your screen assembly production line? Learn more about the AUTOSCREEN production cell today.
Automation is great, but HOW?
Despite its potential, automation adoption in manufacturing is not without its challenges. Many companies face cultural resistance and operational disruptions that can slow or even stall progress. These barriers are especially pronounced in traditional manufacturing environments where legacy systems and manual workflows are the status quo.
Q: How do I integrate automation with existing systems?
Many manufacturers struggle with outdated systems and limited scalability. To overcome this, start by assessing your current infrastructure and identifying areas where automation can add value. Use modular solutions and middleware to bridge legacy systems with modern automation tools.
Q: How do I prepare my people for automation?
Change is hard, especially for employees who’ve been doing things the same way for decades. The key is empathy and education. Offer hands-on training tailored to their roles and highlight how automation simplifies their work rather than replaces it.
Q: How do I reassure my employees that automation won't take jobs?
Transparency is essential. Communicate that automation is meant to eliminate repetitive tasks, not roles. Share examples of how automation has led to job enrichment, not reduction. Involve employees in the transition and emphasize how their experience is vital to making automation successful.
Q: How do I overcome cultural resistance to automation?
Cultural pushback is common, especially in traditional environments. Address it head-on with clear messaging, leadership support, and early stakeholder engagement. Recognize and validate concerns and use change champions and leaders within the organization to build trust and momentum.
Q: How do I manage operational disruptions during automation rollout?
Automation can disrupt workflows and job responsibilities. Effective change management is crucial; map out the impact, communicate changes clearly, and provide ongoing support. Use phased rollouts and feedback loops to minimize disruption and adapt quickly.
Q: How do I ensure automation delivers ROI?
Real-time data access is key. Without it, decision-making slows, and ROI suffers. Invest in systems that enable fast, accurate data collection and analysis.
Curious about implementing automation into your workflow? Dive deeper into how fenestration manufacturers can overcome resistance and accelerate ROI, check out our blog post: https://www.autoscreen.us/blog/automation-in-fenestration-how-to-overcome-the-adoption-hurdle-and-achieve-roi-faster. It offers actionable insights on identifying automation-ready tasks, building internal champions, and leveraging modular systems like AUTOSCREEN to ease the transition.
As the manufacturing landscape continues to evolve, automation is a vital strategic advantage. By embracing innovation and investing in people, manufacturers can build a more resilient, efficient, and future-ready workforce.
