Catching and stacking lumber can make or break productivity at the truss build tables. In an imaginary world where money is irrelevant, a linear saw in front of each automated truss jig would be ideal, cutting pieces in order from, let’s say, 60 ft finger-joined lumber, and robots grabbing each piece as it comes out of the saw, assembling the truss. I’m sure we will get there some day soon. In the meantime, for existing truss plants, a fully loaded RetroC with SpeedCatch is proven to efficiently feed multiple truss jigs and to speed up truss production. [For all photos, See PDF or View in Full Issue.]
The Enventek RetroC SpeedCatch system is powered by sophisticated software that standardizes the auto-filling of paired lumber carts that will collate cut pieces for the left and right side of the truss. PlantOne screens over the truss build tables show the intuitive color-coded cart map and truss pieces, reducing the need for paper at the tables. SpeedCatch uses more carts than traditional manual catching. In this example, 12 carts spread out over 44 ft reduces truss builder travel distance and time to hunt for pieces. Carts are perpendicular to the tables with cut pieces pointed in the correct direction, so pieces are easily pulled onto the table – no “helicoptering” or lifting of pieces overhead.
Enventek SpeedStack is an out-of-the-box solution for computer-aided lumber stacking when SpeedCatch carts cannot be utilized. SpeedStack left, middle, and right collated carts are shown in front of the truss build table. With limited staging space in front of the build table, carts are placed parallel to the table. Some pieces will have to be lifted overhead to get onto the table, however, because of left and right orientation, pieces will not be “helicoptered” onto the table. SpeedStack is sophisticated software that standardizes how to stack lumber onto one or two carts with either one or two catchers – collated for left, middle, and right side of truss. SpeedStack is derived from the SpeedCatch algorithms for manual catching onto flat carts in “layers of unique trusses.”
Most truss plants have created their own cutting and stacking schemes specific to their plant constraints. These “catch-as-catch-can” systems have been implemented by people who will use any means necessary to accomplish their tasks. We too will do what it takes to get lumber in front of the tables, but we can help you improve your systems. Here are some examples of getting the job done. They all work and are all specific to each truss plant.
Vertical tree carts manually stacked will require a lot of pre-planning and the use of several cutting and catching schemes. Training is extensive and requires experienced hard-working catchers. Shown here are vertical tree carts needing two catchers. The filling of left, middle, and right carts depends on span and quantities. Tree carts done properly will help speed up truss building. Pieces will not always be pointed in the correct direction, so there will be “helicoptering” and lifting of pieces overhead even if carts are placed perpendicular to the tables. At the table, pieces will need to be hunted and travel distance could be repetitive depending on span.
Some truss plants have saw shops that are separate from the truss building, rendering carts ineffective and needing a forklift to bring the cut pieces to the tables. Shown here is a solo catcher who stacks cut lumber and then straps the bundles for forklift travel to the build tables.
A lot of truss plants have legacy systems developed over years that may not be as efficient as a standardized system, and have become a cost of doing business. Shown here are traditional flat carts, meticulously hand stacked and placed in front of the truss table that will result in repetitive travel distances between truss setups.
Traditional meticulous hand stacking for left, middle, and right carts can, especially for large quantities of long span trusses, look neat and organized. However, in lean manufacturing, this could be considered wasteful as this requires a lot of labor with experience and expertise which will still need significant material staging time before trusses can be built.
I invite you to come see the differences for yourself! Please join us Wednesday, February 21 for the Feed the Beast! Plant Tour of Tindell’s Truss Plant in Knoxville, TN. Travis White of Tindell’s has graciously agreed to host a tour of his Fully Loaded RetroC: register for the tour online.
Inside and out, LimTek Process Organization Technology will help you squeeze out more truss production and deliver quality trusses with shorter lead times to better service your customers by organizing your truss fabrication processes to maximize your investment in automation.