New approaches to determining mill efficiencies Yvon Corneau, Group leader Lumber Manufacturing
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1 New approaches to determining mill efficiencies Yvon Corneau, Group leader Lumber Manufacturing
2 Sawmill performance Tree Size Consumption Lumber Period Factor Recovery (dm 3 ) (m 3 /Mbf) (bf/m³) Actual Leaders
3 Key elements of an analysis Resource characteristics -Size distribution -Species - Taper - Sweep Technologies Markets
4 Tools Sawing simulation software
5 Tools- Mobile scanner
6 Mobile scanner with 3D technology
7 Configuration of a sawmill with Optitek
8 Sawing patterns for a 4-sided canter 1x4 2x3 1x3 2x3 1x4 2x4 2x4 2x4 2x4 2x4 2x4 2x6 1x4 2x6 2x4 2x6 2x6 2x4 2x6 2x6 2x6 2x6 2x6 2x6 2x8 2x8 2x8 2x8 2x8 2x8 2x8 2x8 2x8
9 Secondary breakdown (curve sawing) Straight sawing Natural curve Sawing Curve Sawing Calculated Polymonial Hybrid Sawing
10 Equipment 1. Primary breakdown (e.g. canter-twin, SLI, DLI ) 2. Secondary breakdown (linear and transverse tables) 3. Edger optimizer 4. Trimmer optimizer 5. Trimmer optimizer at the planer mill (automated linear graders) Équipements 1. Débitage primaire (e.g. canter-twin, SLI, DLI ) 2. Débitage secondaire (tables linéaire et transversale) 3. Délignage optimisé 4. Éboutage optimisé 5. Éboutage optimisé au rabotage (classeurs linéaires)
11 Scanner Verification Vérification d'un scanneur
12 Quick Scanner Check-up Vérification rapide du scanneur 1 st pass. 2 nd pass. 3 rd pass. Average Moyenne Ave. Dev. Écart moy. Max. Variation 4 in. Pipe Tuyau de 4 po. 4,2 4,0 4,1 4,1 + 0,1 + 0,2 8 in. Pipe Tuyau de 8 po. 8,1 8,3 7,8 8,1 + 0,1 + 0,3 An average deviation of 0.1 in is acceptable A maximum variation of 0.3 in is excessive Un écart moyen de 0,1 po est acceptable Un écart maximum de 0,3 po n est pas normal
13 Log Positioning Positionnement des billes Emploi du scanneur mobile : Déterminer le centrage, la rotation et les caractéristiques géométriques avec une grande précision Use of the mobile scanner: To check log centering, rotation and to measure accurately real log characteristics
14 Evaluation of a Log Turner Évaluation d'un tourne-billes 17 mm 5 19 mm
15 Log Positioning Rotation Errors for 8 Industrial Log Turner Positionnement des billes Erreurs de rotation pour 8 tourne-billes industriels Rotation error STD ( )
16 Log Positioning Positionnement des billes 70% 60% 50% Log Turning is Not Better With Straight Logs Crooked Logs (> 1 in) Straigth Logs 40% 30% 20% 10% 0% Rotation Error ( )
17 Economic impact of log rotation errors Belt Infeed Optimised Offset Centering Rolls Optimised Offset + Skew Standard Deviation of Rotation Errors
18 Global Canter Efficiency Efficacité globale des équarrisseuses Performance Simulated Performance théorique Mill Performance réelle $/m % 91 % 92 % % Belt Infeed Centering Optimised Optimised Rolls Offset Offset + Skew
19 Reasons for losses Scanning errors Log turner errors Movement in transport system Fiber tear out
20 Positioning test at Optimized Gang Edger Test de positionnement à une débiteuse Position de la scie zéro Position Zero Saw Position de la scie zéro
21 Positioning Errors (infeed table) Erreurs de positionnement (table d'alimentation linéaire) 35% 30% 25% Rear offset / Décalage arrière Front offset / Décalage avant 20% 15% 10% 5% 0% Positioning errors (in) Erreurs de positionnement (po)
22 Optimizers Parameters Paramètres des optimiseurs Sawn Thickness Largeur sciée Optimized Thickness Largeur optimisée Concept «piece within the piece» «pièce dans la pièce» Optimized Width / Largeur optimisée Sawn Width / Largeur sciée
23 Measuring Wane Tolerance Mesure de la flache permise Dimension Grade Min. Thickness Épaisseur min. Edge Wane Flache épais. Min. Edge Bon bois épais. Min. Width Largeur min. Face Wane Flache larg. Min. Face Bon bois larg. 2x6 No % % x6 No 2 equiv % % Edge Wane Flache en épaisseur Face Wane Flache en largeur
24 Edger efficiency Type of operation Manual edging 1 Optimised edging 2 10 à 15 pcs/min 30 à 35 pcs/min Type of errors Over-edged (%) Under-edged (%) 2.8 Mis-edged (%) Total number errors (%) Volume efficiency (%) Volume loss (%) Value efficiency (%) Value loss (%) Evaluation of 9 manual edgers(mills 60 MMbf +) 2 Evaluation of one optimised edger.
25 Edger errors-what they represent for a 60 MMbf sawmill Manual edging Optimised edging Benefits Total errors 46,9 % 20,0 % 26,9 % Volume loss/yr 1,9 MMbf 500 Mbf +1,4 MMbf ( 3,2 %) ( 0,8 %) (+2,4 %) Value loss/yr $ $ $ ( 3,3%) ( 1,2%) (+2,1%) Average lumber value : 350 $/Mbf
26 Trimmer efficiency Optimised trimmer 2 Optimised trimmer 3 Manual laser spacings laser spacing Type of operation trimmer 1 (2 à 6 inches) (1 inch) 50 à 60 pcs/min 90 à 100 pcs/min 90 à 100 pcs/min Type of errors Over- trimming (%) 26,0 7,8 7,8 Under-trimming (%) 6,0 5,7 3,5 Mis-trimmed (%) 2,2 8,7 1,8 Total errors (%) 34,2 22,2 13,1 Volume efficiency(%) 93,8 98,7 (96,3) 99,4 (98,6) Value efficiency (%) 91,8 94,5 (98,7) 97,6 (98,8) 1 Résults from evaluation of 11 manual trimmers ( 60 MMbf +). 2 Résults from evaluation of 4 optimised trimmers. 3 Résults from evaluation of 3 optimised trimmers. ( ) Potential efficiency after planing.
27 What does this mean for a 60 MMbf sawmill Manual Optimised Benefits Total errors 34,2 % 13,1 % 21,1 % Volume loss/yr 4.1 MMpmp 800 Mpmp +3,3 MMpmp ( 6,9 %) ( 1,4 %) (+5,5 %) Value loss/yr $ $ $ ( 6,8 %) ( 1,3 %) (+5,5 %) Average lumber value : 350 $/Mbf
28 Examples of Results Performance Indicators Sawmill Production (million bf) Lumber Recovery (fbm/m³) Economic Improvement (%) Additional Revenue (million $) Actual Sawmill Adding an optimized board edger to actual sawmill Optimized canter-twin with straight gang edger Optimized canter-twin with S curve gang edger Optimized canter-twin with S curve gang edger plus an optimized 3-saw board edger Optimized canter-twin with natural curve canter-gang edger Optimized canter-twin with natural curve canter-gang edger plus an optimized 3-saw board edger
29 Optitek Applications 1. Mill Modernisation & Improvements New technologies (optimisation, curve sawing) Reduced saw kerfs, target sizes, sawing patterns, new products 2. Fibre Audit Performance validation, lumber recovery, chips, sawdust, shavings 3. Market Analysis Export markets, value-added products 4. Resource Evaluation Potential volume and value recovery, bucking scenarios Comparison of different sources 5. Performance Evaluation Percent efficiency, scanner precision, positionning 6. Productivity Analysis Pieces/minute at machine centers
30 Recommendations Check scanner calibration regularly (once a week) Ensure control of all optimization parameters Carry out complete diagnostic (1 or 2 times a year) Calibrer ou vérifier régulièrement les scanneurs (1 fois par semaine) S assurer de maîtriser les paramètres d optimisation Effectuer un diagnostique complet à l occasion (1 ou 2 x par an)
31 Recommendations Perform periodic controls on small samples (5), and cumulate results over one week or one month periods Use the experience acquired to implement a quality control program Effectuer des contrôles périodiques sur de petits échantillons (5), et cumuler les résultats sur des périodes d une semaine ou d un mois Utiliser l expérience acquise pour mettre en oeuvre le programme de contrôle de qualité
32
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