applying qc principles in lumber drying
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Applying QC Principles in Lumber
Drying
Peter Garrahan
New England Kiln Drying Association
March 27-28, 2013.
West Lebanon, NH
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Applying QC Principles in Lumber Drying
Famous Quotes Concerning Quality Control
To improve is to change: to be perfect is to
change often.
Winston ChurchillWinston Churchill
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Applying QC Principles in Lumber Drying
• If you can’t measure it, you can’t manage it. Peter Drucker
•We need to learn to measure what is important,
not to treat what we can measure as important. ????
• So let’s focus on some of the things that we can
measure as related to drying and that are significant
with regard to the productivity of the process or
quality of the final product.
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Applying QC Principles in Lumber Drying
Where to Focus?
Process Product
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Applying QC Principles in Lumber Drying
Process Variables
• Preparation of lumber for Drying
• Kiln Operation
• Physical condition of kiln
Product Quality
• Final MC
• Straightness
• Minimal checking
• Coloration
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Process Variables
Preparation of Lumber for Drying
• Stacking
• Stickers
• Alignment
•Missing
• Placement• Placement
• Other issues??
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Process Variables
Preparation of Lumber for Drying
• Kiln Loading
• Placement of packages
• Alignment of bunks with stickers
• Maintaining a chimney
• Blocking openings through load• Blocking openings through load
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Process Variables
Preparation of Lumber for Drying – how to measure/monitor
• Regular inspections
• Set targets – don’t expect 100% conformance
• Determine % of conforming product• Determine % of conforming product
• Record and track results
• Control charts
• More formal QC programs i.e. FPInnovations
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Process Variables
Charge No. __________ Kiln No. _______________ Date: _______________ Inspection by: ________________________
Material Dimension: ____________________ Rows/bundle: _____________ Bundle Width: ________________
Pakckage
# Length
Bunks Stickers Boards Other Comments or
Observations Missing Mis-aligned Missing Mis-aligned Doubled up Missing Unsecured
Inspection Form - example
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Process Variables
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Mill ABC Forest Products Inc.
Perf. Indicator 88.2 Drying Related Practices
Process Variables
Perf. Indicator 88.2 Drying Related Practices
1 Stacking and Stickering (30%) 93.4
2 Green Lumber Yard (20%) 73.6
3 Kiln Loading (40%) 95.3
4 Dry Lumber Yard (10%) 73.6Your Mill
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Process Variables
USDA – Forest Products Lab
• Inspection program called IMPROVE (?)
• Included checklists and scoring systems for performance
in various areas related to drying.in various areas related to drying.
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Process Variables
Kiln Operation – how to measure/monitor
• DB temperature – accuracy, uniformity
• Hardwood kiln +/- 1 to 2°
• Softwood (dimension lumber) =/- 4 to 5°
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Process Variables
Kiln Operation – how to measure/monitor
•WB/RH – accuracy, uniformity
• Airflow – level & uniformity• at low air flows +/- 50 fpm from average
•at higher air flows +/- 100 fpm
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Process Variables
Physical Condition of Kiln – how to measure/monitor
• Condition of baffles
• Condition of doors/gaskets
• Operation of vents (closing/opening fully)
• Leaks around kiln structure• Leaks around kiln structure
• etc.
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Process Variables
No. 1 Objective of Kiln Operator Should Be to:
Operate and maintain the kilns in a manner that every
board is exposed to (as much as possible) the same
drying conditions.drying conditions.
What did Henry Ford have to say:
“Quality means doing it right when no one is looking”
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Prodcut Quality
Product Quality
• Final MC
• Straightness
• Minimal checking• Minimal checking
• Coloration
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Product Quality
Final MC Monitoring
Statistics are good:
• Average
• Standard Deviation
Average +/- 2xS.D. = 95%
• COV – coefficient of variation
normal distribution
• COV – coefficient of variation
- standard deviation expressed
as a percentage of average
i.e. Average = 8.0% & SD = 1.0%
COV = 1/8*100 = 12.5
Basic statistics work good on a
“normal distribution”
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Product Quality
Final MC Monitoring
- often in drying we are dealing with a “non-normal” or
“skewed” distribution
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Product Quality
Final MC Monitoring
- look at % of material below specified final MC
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Product Quality
Product Quality
• Straightness
• Minimal checking
• Coloration
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Product Quality
Product Quality
• Softwood mills can now track warp-related
degrade and relate back to specific charges
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Product Quality
Product Quality
• Tracking incidence of drying-related defects allows
us then to use tools such as control charts to identify
when the process is going out of control and action
is required.
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Applying QC Principles in Lumber Drying
“When people and organizations focus
primarily on costs, costs tend to rise and
quality declines over time.” W.E. Deming
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Applying QC Principles in Lumber Drying
• Monitoring and measuring helps develop a better
understanding of the process/product.
• A better understanding helps you set realistic targets
for each part of the operation
• Personnel tend to respond better when they know the
targets and receive feedback on their performance.
“If one does not know to which port one is
sailing no wind is favorable.” Lucious Annaeus Seneca
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Applying QC Principles in Lumber Drying
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Have no fear of perfection -you'll never reach it. Salvador Dali
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