Should we cull lumber at the saw? That is the question posed by Joe Kannapell, P.E. in The Last Word in the July issue, “Where to Cull Lumber.” As Joe discusses: “So where in the process should we cull lumber? To minimize touches, it can be done when the bands are broken on a fresh bunk of lumber.” He goes on to say, “A better method may be for a linear saw operator to observe each board on the live deck. The operator has the best vantage point from which to cull lumber, and he can do it while boards are cycling into the saw’s infeed.” However, Joe surmises, “having the saw operator manage your culling may run contrary to the ‘right the first time’ principle...”.
Whether it is a component saw or a linear saw, the sawyer always has the “last look” to re-crown or re-orient the lumber, and the sawyer also needs to check the work of the lumber picker to make sure the lumber size, length, grade, and piece count matches the order of the cutting list. If the sawyer has to cull any lumber, this will affect saw productivity by having to replace the culled lumber and will also result in ongoing extra effort to clear the saw area of culled lumber. [For all photos, See PDF or View in Full Issue.]
The first picture shows an overview of the Enventek Lumber PickLine consisting of the SmartConveyor feeding the saw and the PickLine lumber trough loaded with full bunks of lumber to efficiently feed the SmartConveyor. The lumber on the front deck is ready for the sawyer to have the “last look.” Culled lumber stays out at the Lumber PickLine, which can be dealt with more productively away from the saw. (Note the dense lumber storage shed in the first picture used only to replenish the bunks on the PickLine lumber trough. Lean Manufacturing Tip: Avoid using dense lumber storage for picking lumber, with or without a PickLine.)
Indoor or outdoors, it is easy to see how an Enventek Lumber PickLine reduces the reliance on forklifts, resulting in ongoing and significant operating cost savings. Forklift operators should not be lumber pickers, and the use of lumber pickers is more cost effective than having to staff certified forklift operators. Teaching a lumber picker how to pick lumber using the PickLine’s WiFi-connected tablet can be accomplished in less than 30 minutes and anyone can do it, and anyone can be cross trained. The PickLine also has sensors to count each board as well as check the board length and board size against the picklist/cutting list. Making sure the correct lumber grade is used is all on the lumber picker, and then the sawyer gets the “last look” as the final QC check.
The benefits of upgrading existing forklift-fed saws with an Enventek Lumber PickLine are immediate. Within three (3) days of installation and training, the cost savings and valuable reclamation of saw idle time will be accomplished. (For an example, see my previous article, “A Weekend Install and a Packers Home Game.”)
Yes, any automated saw, be it linear or component saws, can be upgraded with a PickLine. For more on that, just check out my article from June, “Automation Elements That Can Benefit Any Size Truss Plant.”
We can also consider the advice of another of my fellow authors in these pages, Glenn Traylor. As he has asked, “Where is Your Focus on Manufacturing?” Glenn reminds us to focus on quality manufacturing, and a PickLine feeding any saw will inherently improve the quality of lumber that reaches the saw, which will result in reduced re-cuts, which further reduces operating costs. As Glenn emphasizes, “Maintaining quality and focusing on Value should be your key objective. Improving quality starts with implementation of the ANSI/TPI 1 standard—and, with that process, you will improve proficiency and speed. Controlling wasted efforts and rework of product will reduce your costs too.” A PickLine will help maintain quality and keep your people focused on providing value, which begins at picking lumber (and at the tables).
The PickLine’s lumber trough is a natural quality control device to help handle variations in lumber quality as any board that gets “stuck” in the trough is just not fit to be utilized in a truss.
So boards that are too crooked will be culled at the PickLine. That will help you maintain fabrication tolerances, the importance of which Glenn also reminded us of earlier this year in “How Do You Determine Fabrication Tolerances During Design?”
So, to cull or not to cull is not the real question. Of course, you have to cull lumber. Whether you cull at the saw or not, however, can potentially make or break your production. Culling lumber out at the PickLine will boost saw productivity, which will also boost truss building productivity by reducing recuts. The question is really to forklift pick or to PickLine pick? To forklift pick means to pick lumber from dense storage, unless a short lumber pick area is created, which could be upgraded to an Enventek Lumber PickLine. If picking lumber with a forklift from dense storage, chances are lumber will have to be culled at the saw, slowing down saw production and resulting in wasted forklift travel back to the dense storage and then back to the saw to replace the culled lumber.
Enough with the pondering! 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