Kanban systems are designed for “just in time” workflow to optimize production efficiency and inventory levels. The Enventek Lumber PickLine is essentially a “Giant Kanban System” designed to improve lumber handing and to efficiently cull lumber away from the saws. Did you know that the main design criteria of the PickLine was to improve truss build production by having the lumber picker follow the tablet picking software to facilitate the organization of cut lumber in front of the truss build tables? With Enventek’s invention of the auto-feeding RetroC and auto-catching SpeedCatch carts, the system was too efficient for ordinary arrangements to keep up, and “one could not feed the beast even with multiple forklifts running around all day fetching lumber.” Hence, Larry Dalson invented the Enventek Lumber PickLine. [For all photos, See PDF or View in Full Issue.]
In the first picture, one can see how a forklift followed this path to get lumber to the saw — now that’s been replaced with a “passive lean” PickLine and SmartConveyor. No Kanban card system required (Giant Kanban!). Everyone can easily see what lumber needs to be refilled and what lumber is getting depleted. Please note the lumber storage shed and the dense storage lumber in the background. Daily picking lumber is not lumber storage. Lumber PickLines can feed any automated saw with the same benefits of more productive cutting/batching schemes and of increased sawing production by eliminating saw idle time.
There’s always room for an Enventek Lumber PickLine by strategically placing the lumber chain trough on an existing forklift path. This saves on operating costs by significantly reducing forklift travel and by replacing a dedicated forklift operator with a dedicated lumber picker. The important process of culling lumber at the PickLine away from the saw will improve sawing throughput with better quality lumber — for another example, see my article, “To Cull or Not to Cull (at the Saw).”
Space limitations in front of truss build tables require hand-stacked lumber to be organized for “left, right, and middle” of truss to speed up truss building as shown in the next photo. Without a Lumber PickLine, these truss building cutting schemes would be difficult to “pick” and would require a lot of communication between the sawyer, forklift picker, and lumber stackers. Having the software determine the lumber picking based on the detailed stacking sequence of lumber standardizes the material handling workflow and streamlines teamwork.
There are many tips and guidelines on how to envision and layout a lumber PickLine in my article, “The Art of a Lumber PickLine.” The only space limitation is how close the lumber trough can be placed alongside your existing building/driveway! The general rule is 35 ft from the building to the centerline of the lumber trough, if there is limited or no overhead door access along the side of the building. This is so forklifts can easily replenish lumber along the building side. To get more building clearance access, increase the length of the Smart Conveyors up to 80 ft long, which gives plenty of building access. In the next picture, because this plant has a Side-Loading Forklift and they wanted to keep the existing driveway as open as possible, they put the centerline of the lumber trough to the building at only 16 ft.
Even with a “Single-Sided Lumber Trough,” this customer is boasting a 30% sawing increase compared to their previous forklift lumber picking following the same path with significant operating cost savings. As shown here, the lumber is two bunks wide (different grades/sizes) and the picker manages the picking lumber accordingly.
Most importantly, the Lumber PickLine never cares what type of saw you have! Of course, I can personally recommend the RetroC, but you can read about other options too in my article, “Feed Any Component Saw with a Lumber PickLine.”
When you’re ready to Feed Your Beast and see these efficient and effective systems for yourself, let us know! 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. https://limteksolutions.com/#solutions