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

Decay Inside a Knot

Heart Rot___________

Sap Wood______I

Heart Check____________________

Heart Wood_______________

Sound

Knot

__________|

Decay__________|

Defect Identification on Cross-sectional Views

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

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

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%

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

• With a fast solution algorithm and smart programming, a real time optimization software has been developed

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

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)

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%

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%

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

• 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.

Only the Paranoid survives

• Our competitors also recognize that, particularly our Canadian friends up north.

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.

• 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.

• Forintek Canada has embarked on a sawing optimization project similar to TOPSAW to establish firmly the competitive edge for the Canadian hardwood sawmill industry.

• It is time to establish a Hardwood Sawing Technology Center, make TOPSAW a reality, and regain the competitive edge.

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

• Cost over 4 years

• With sawmill equipments

$3.5 million

• Without sawmill equipments

$2.5 million

TOPSAW Benefits

Individual Sawmills

Sawmill Industry

Nation

Increased Profit

StrengthenedGlobal

Competitiveness

Enhanced Resource

Conservation

Consumers

Improved LumberQuality