Humans at the Helm: Innovation, AI, and the Future of Hardwood

Walk into a hardwood mill today, and you might find more than sawdust and grit. You’ll find smart cameras, robotic arms, and data dashboards quietly transorming how people work. New vision systems and robotics aren’t here to edge out seasoned crews, but to amplify their skill, give them safer tasks, and connect them to the bigger picture of production.

Still, not everyone feels at ease about the shift. A recent Microsoft Work Trend Index found that 53% of people who use AI at work worry that using it on important tasks makes them look replaceable (Microsoft, 2024). That tension is exactly why this conversation matters. While AI is a major driver of this transformation, it’s part of a broader wave of new technologies, automation, robotics, sensors, and smarter systems that are reshaping how work gets done. In hardwood, innovation isn’t about replacing people. It’s about refining how craftsmanship and technology work side-by-side. And nowhere is that balance clearer than on the mill floor, where companies like Zira and Sync Robotics are blending human judgment with smart, responsive tools to make every-day production faster, safer, and more connected.

THE MILL VIEW IN REAL TIME
Zira, an AI vision company, has developed AI-based, universally sensing-mounted cameras that watch the process the way a great supervisor would, only they never blink. The system detects boards, measures dimensions, counts throughput, and tracks safe-zone behavior. Managers get realtime performance dashboards showing Overall Equipment Effectiveness (OEE) and Overall Labor Effectiveness (OLE), while operators track their progress and targets on a screen right in the cab.

“We consistently see 30% more throughput once operators and managers have real-time data,” says Elhay Farkash, CEO of Zira. “And dynamic cut plans add about a 5% yield improvement.”

Instead of stepping away from the saw with a tape measure and flipping through a wall chart, a sawyer now views a live cut plan directly on-screen—3 x 52.5 in—and gets on with cutting. The hardware is simple (camera + display), installation is quick, and the upside is immediate: fewer stoppages, tighter cuts, and a crew that knows exactly how the day is going now, not after shift end.

RIGHT-SIZED ROBOTS FOR HARDWOOD REALITIES
Hardwood lines run at a more deliberate pace than softwood operations—prioritizing precision, quality, and yield over sheer speed. That’s good news for robots. Sync Robotics, a custom robotic system integrator, designs cells that match your actual rate—50–80 boards per minute, not 200+. Projects range from ~$100k single-task cells (labeling, stacking, stapling) to multi-million-dollar heavy-lift systems.

“Hardwood doesn’t require the 200 boards per minute or more that a typical softwood producer would require,” says Tyler Boulley, Sales Director at Sync Robotics. “Give us your toughest, most repetitive job. If a robot can take it, your veterans can stay longer and focus on quality and safety.”

Sync Robotics emphasizes documentation and training so plants can own their equipment. That helps with staffing, too: many regions struggle to hire line labor but can attract automation techs who prefer stable roles overseeing several cells.

MEMBER PERSPECTIVE: SEEING THE BIGGER PICTURE
Allen Keller of Keller Lumber & Logging says the biggest change from adopting newer tools hasn’t just been production and planning, it’s mindset.

“Once they’re able to see the bigger picture—what goes on beyond their part in production with these tools—they become more aware of how they impact more than just their role.” —Allen Keller, Keller Lumber & Logging.

Keller’s perspective came after participating in the NHLA’s Yield Analysis Study, which measured the efficiency of his mill in turning logs into lumber. The results revealed untapped potential and inefficiencies, prompting Keller to explore advanced technology as a way to bridge the gap. By combining NHLA’s data-driven insights with new digital tools, he was able to translate findings into action and elevate production standards.

Keller’s point shows up on the floor as fewer bottlenecks and better handoffs. When operators can see upstream and downstream status and daily targets, they avoid “tunnel vision,” adjust sooner, and collaborate across stations.

FROM SKEPTICISM TO BUY-IN
Fear of job loss is real. Sync Robotics’ first install met resistance: workers wore “union strong” shirts and sabotaged equipment at night. No one got laid off. Two people were trained to run what had taken six to eight; they earned raises and new titles in Quality Control and oversight. On the next project, the same crew asked, “Can you put a robot on this line, too?”

“AI didn’t replace operators—it gave them targets and tools,” Boulley adds. “People started competing with their own best day.”

TRAINING THAT STICKS
Both Zira and Sync Robotics argue the secret is early, collaborative training: bring in operators, leads, maintenance, and management; make the data visible; set clear daily targets; and document so the plant isn’t dependent on outside help. As NHLA member Allen Keller notes, operators stop working in silos and start acting on the bigger picture, which lifts quality and throughput across shifts.

WHAT IT COSTS—AND WHAT IT RETURNS
Zira’s AI vision hardware and software costs a few thousand dollars, depending on the number of cameras needed, and pays for itself rapidly through downtime avoided and yield gained. For robotics, Sync Robotics’ “right-sized” scope keeps capex in line with hardwood volumes. The results NHLA members care about—fewer injuries, higher retention, steadier output, and promotable skills—are where these systems shine.

BOTTOM LINE
The hardwood industry’s craft isn’t going anywhere. What’s arriving—quietly, helpfully—is a set of tools that let experienced people do more of what they do best.

CONTACT INFORMATION
NHLA Yield Analysis Study — Unlock your mill’s full potential with a Yield Analysis at 75% off; contact Chief Inspector Dana Spessert at [email protected] to learn how data can reveal hidden efficiency gains.

Zira — Turn everyday mill activity into actionable insight with AI-powered vision systems that boost throughput, safety, and real-time awareness. Learn more at joinzira.com.

Sync Robotics — Automate your most repetitive, high-risk jobs with custom robotic solutions built for hardwood-scale operations. Discover how at syncrobotics.ca.

Keller Lumber & Logging — A long-standing NHLA member sawmill in Stevenson, Alabama, delivering quality green lumber and byproducts from trusted hardwood species. Connect with Allen Keller at [email protected] or call (256) 437-3155 to learn more.

Sources:
Microsoft Work Trend Index. AI at Work Is Here: Now Comes the Hard Part. Microsoft, 2024. https://www.microsoft.com/en-us/worklab/work-trend-index/ai-at-work-is-here-now-comes-the-hard-part

By BRENNAH HUTCHISON, Hardwood Industry Liaison & Content Director