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A A TTraining and raining and OPOPtimization System for Log timization System for Log SAWSAWinging
Sun Joseph ChangSchool of Renewable Natural Resources
Louisiana State University Agricultural CenterBaton Rouge, LA 70803
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Decay Inside a Knot
Heart Rot___________
Sap Wood______I
Heart Check____________________
Heart Wood_______________
Sound
Knot
__________|
Decay__________|
Defect Identification on Cross-sectional Views
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Results of Replication of Log #3Board Sawmill Results TOPSAW Results
ID Board Size BF Grade Value Board Size BF Grade Value
A1 6.25”x 12’ 6 FAS $6.34 6.3”x 12’ 6 1C $3.72
A2 10”x 12’ 10 1C $6.20 9.8”x 12’ 10 1C $6.20
A3 6.25”x 9.15’ 5 FAS $5.20 6.95”x 9.15’ 5 FAS $5.20
A4 8.25”x 12’ 8 FAS $8.32 8.4”x 12’ 12 FAS $8.32
A5 10.25”x 8’ 7 FAS $7.28 10”x 8’ 7 FAS $7.28
A6 5.25”x 12’ 5 SEL $4.00 6.2”x 12’ 6 SEL $4.80
A7 7.25”x 12’ 7 FAS $7.28 7.3”x 12’ 7 FAS $7.28
A8 6.75’x 12’ 7 F1F $6.93 7.2”x 12’ 7 F1F $6.93
A9 7.25”x12’ 7 1C $4.34 7.3”x 12’ 7 1C $4.34
Cant 7”x 6”x 12’ 42 NA $10.50 7”x 6”x 12’ 42 NA $10.50
Total $66.29 $64.57
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Details of the seven red oak logs scanned
Log # Grade Large End Diameter
Small End Diameter
Length Board Feet
(Inches) (Inches) (Feet) (BF)
1 1 17.50 14.13 11.75 69
2 1 17.50 12.75 11.92 44
3 1 14.25 13.75 11.92 56
5 2 14.00 13.00 12.67 61
6 2 11.62 11.00 12.42 37
7 2 14.75 13.88 12.25 61
8 2 14.88 14.13 12.25 75
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Comparison between sawmill and simulation results
Comparison 1 Comparison 2 Comparison 3
Simulation Results $479.05 $497.26 $356.62
Sawmill Results $422.06 $422.06 $278.42
Percent Gain 13.5% 17.8% 28.1%
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Challenges for the Internal Defect Based Sawing Optimization System
• Hardware: A fast, more powerful, strong, durable, and low cost scanner
• Software: A fast optimization software
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• With a fast solution algorithm and smart programming, a real time optimization software has been developed
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Optimal Cutting Sequence• Cut No. Thickness Volume Grade Value (in
inches) (in board feet) ($)
• 1 4/4 6.5 1C 4.00• 2 5/4 12.9 FAS 12.77• 3 6/4 17.4 1C 14.09• 4 8/4 26.0 1C 21.73• 5 6/4 20.0 1C 16.26• 6 6/4 18.8 1C 15.21• 7 5/4 14.3 FAS 15.54• 8 6/4 13.4 FAS 15.31• 9 4/4 5.4 1C 3.31
»
» Total Volume 134.8 BF Total Value $118.22
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Results related to Log #3
• Sawmill production: $66.29
• TOPSAW replication: $64.57
• TOPSAW simulation: $91.32
(+ 37.8% over sawmill production)
• TOPSAW optimization: $118.22 (+29.5% over simulation, +78.3% over sawmill production)
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A comparison between live sawing optimization and sawmill production • Log Live sawing Sawmill• Optimization Production• Log 1 $92.35 $84.20• Log 2 $94.97 $69.91• Log 3 $118.22 $66.29• Log 5 $100.48 $64.81• Log 6 $74.25 $32.42• Log 7 $45.23 $59.44• Log 8 $63.23 $41.81• Average Gain 40.5%
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A Comparison between Live Sawing and Bi-directional Sawing Optimization
• Log Live Sawing Bi-directional Sawing• Optimization Optimization• Log 1 $92.35 $93.94• Log 2 $94.97 $107.7• Log 3 $118.22 $122.73• Log 5 $100.48 $107.9• Log 6 $74.25 $74.8• Log 7 $45.23 $53.6• Log 8 $63.23 $71.3• Average gain of bi-directional over live sawing 7.3%
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Why we need TOPSAW• Log cost accounts for about 60% of the hardwood
lumber production cost based on the data of the 1997 Census of Manufactures
State Cost of Value of log cost as a %
Materials Shipments of shipments
IN 119395 211461 0.56
KY 221508 391409 0.57
MO 148512 241356 0.62
OH 154080 260451 0.59
PA 432503 720675 0.60
WV 255149 422082 0.60
mean= 0.59
std= 0.02
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• increasing log conversion efficiency, therefore, produces a significant gain in lumber revenue and mill profit
• It holds the key to the competitive advantage in the future.
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Only the Paranoid survives
• Our competitors also recognize that, particularly our Canadian friends up north.
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Only the Paranoid Survives
• Canadian softwood sawmills already have an edge over their U.S. counterparts.
• Despite a 27% import tariff, Canadian softwood sawmills can still undercut domestic producers in the US market.
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• In terms of hardwoods, over the last 10 years, US hardwood log exports doubled and Canada’s share of the export increased from 59% to 70%. As a result, more than ever US hardwood logs are sawn into lumber in Canada.
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• Forintek Canada has embarked on a sawing optimization project similar to TOPSAW to establish firmly the competitive edge for the Canadian hardwood sawmill industry.
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• It is time to establish a Hardwood Sawing Technology Center, make TOPSAW a reality, and regain the competitive edge.
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Hardwood Sawing Technology Center
Goal: To commercialize TOPSAW in 3-4 yearsObjectives:
1. Develop a $5-600,000 per unit CT log scanner
2. Refine the optimization software3. Develop a log set-up system to accurately
and quickly orient and position the log for sawing
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• Cost over 4 years
• With sawmill equipments
$3.5 million
• Without sawmill equipments
$2.5 million
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TOPSAW Benefits
Individual Sawmills
Sawmill Industry
Nation
Increased Profit
StrengthenedGlobal
Competitiveness
Enhanced Resource
Conservation
Consumers
Improved LumberQuality