Marion Body Works implemented two major automation systems at its Shawano, Wisconsin, facility, reinforcing the company’s commitment to higher-quality products and fast delivery for customers. The fully automated bonded sheet and post wall assembly system and an automated floor assembly gantry system encompass innovative firsts in commercial truck body manufacturing. Together, these systems transform previously manual, labor-intensive processes into streamlined, highly controlled operations that improve quality and consistency, and increase throughput on its assembly lines, while also creating a safer overall work environment.
The new wall automation system consolidates multiple manual steps, including material preparation, fastening, bonding, and sealing into a single, integrated process using advanced robotics. The innovation also introduces plasma treatment technology, which enhances adhesion and long-term durability of the walls and truck bodies overall. The automated floor assembly gantry system replaces manual drilling and fastening with a servo-controlled, automated process that ensures precise, repeatable fastener placement across each unit. The router capabilities of the floor system further improve accuracy, fitment, and appearance of pipe pockets and D-rings.
“We’ve refined the process of building truck bodies. The fully automated wall assembly and plasma-treated bonding put us at the forefront of innovation in the commercial truck body market. This investment allows us to safely and consistently build a higher-quality product and deliver it even faster to our customers,” said Kevin Ignacio, president of Marion Body Works.
Customer Advantage
The automation investment is already delivering meaningful operational improvements and measurable advantages for Marion Body Works customers.
- Enhanced quality and consistency: The automated processes reduce variability in drilling, fastening, sealing, and material preparation.
- Increased throughput and efficiency: Consolidated processes and predictable cycle times enable higher output with less reliance on manual labor.
- Reduced lead times: Increased production capacity allows the company to deliver trucks to customers faster, helping keep fleets on the road.
- Precision customization: The precision enabled by the automated floor system supports more accurate and customizable builds, further enhancing the ability to meet evolving customer needs.
- Improved safety: The floor assembly area has recorded zero incidents since automation was implemented.
Investing in People and the Future
Alongside the technology investment, Marion Body Works has made significant contributions to workforce development. Employees have undergone robotics and automation training, including programs with industry partners and technical colleges, to support the transition to advanced manufacturing. The shift to automation has transformed roles within the facility, adding new skills-based opportunities, including operator and technical positions.
“We’re not just investing in equipment; we’re investing in our future,” said Zach Brockdorf, senior director of operations in Shawano. “Our trucks get the job done in important industries, but that's only possible thanks to our team. By creating ways our people can grow their skills and stay safer on the job, we're making a concerted effort to maintain a positive work environment and retain talent for the long term."
Building for Continued Growth
The floor drill system was installed in November 2025, followed by the wall automation cell, which became operational in April 2026. The automation project is part of a broader strategy to modernize operations and support long-term growth, with additional automation projects planned at other facilities. By reducing process variability, improving product quality, and increasing production capacity, Marion Body Works is well-positioned to meet growing demand while maintaining its focus on safety, reliability, and customer satisfaction.
Learn more about Marion Body Works at https://www.marionbody.com.