This thesis presents the development of a model for a unique bin packing and stacking of parts.The methodology developed is applied to a problem in a manufacturing industry wherein roof trusses for residential and industrial building are assembled after being cut on a computer-controlled saw. The truss members will be stacked into several bins using a custom developed algorithm that optimizes several objectives, namely: bin packing, stability of sorted and stacked parts within the bin, and sequencing of stacking within the bins to facilitate assembly process. The testing, verification and performance evaluation using simulation/implementation in a robotic cell is also presented. The goal is to optimize bin packing by allowing truss members to overhang beyond the edges of the bins while maintaining the stack stability. The overhanging of parts is never considered in standard bin packing problem. The application considered in this thesis will benefit from including this option. The method is simulated in ‘Unity’, a gaming software and ‘Octopuz’, a simulation software. The methodology has been implemented in a robot cell. The motivation for this work as noted earlier stems from a need in a local truss manufacturing industry. The methodology is capable of providing a complete automation solution for sorting truss members in similarly operating lumber industry. Based on the tests, the methodology has shown very promising results with 30% decrease in stacking time per part as compared to a previously completed work.