A Training and OPtimization System for Log SAWing
Sun Joseph Chang
School of Renewable Natural Resources
Louisiana State University Agricultural Center
Baton Rouge, LA 70803
Defect Identification on Cross-sectional Views
Heart Rot
___________
Decay Inside a Knot
Sap Wood
______I
Sound
Knot
__________|
Heart Check
____________________
Heart_______________
Wood
Decay
__________|
Results of Replication of Log #3
Board
Sawmill Results
ID
Board Size
BF
A1
6.25”x 12’
A2
TOPSAW Results
Grade
Value
Board Size
BF
Grade
Value
6
FAS
$6.34
6.3”x 12’
6
1C
$3.72
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
7”x 6”x 12’
42
NA
$10.50
7”x 6”x 12’
42
NA
$10.50
Cant
Total
$66.29
$64.57
Details of the seven red oak logs scanned
Log # Grade Large End
Diameter
(Inches)
1
1
17.50
Small End
Diameter
(Inches)
14.13
Length
(Feet)
11.75
Board
Feet
(BF)
69
2
3
5
1
1
2
17.50
14.25
14.00
12.75
13.75
13.00
11.92
11.92
12.67
44
56
61
6
7
8
2
2
2
11.62
14.75
14.88
11.00
13.88
14.13
12.42
12.25
12.25
37
61
75
Comparison between sawmill and
simulation results
Comparison 1
Simulation
Results
Sawmill
Results
Percent
Gain
Comparison 2 Comparison 3
$479.05
$497.26
$356.62
$422.06
$422.06
$278.42
13.5%
17.8%
28.1%
Challenges for the Internal Defect Based
Sawing Optimization System
• Hardware: A fast, more powerful, strong,
durable, and low cost scanner
• Software: A fast optimization software
• With a fast solution algorithm and smart
programming, a real time optimization
software has been developed
Optimal Cutting Sequence
• Cut No.
•
•
•
•
•
•
•
•
•
Thickness
(in inches)
1
2
3
4
5
6
7
8
9
4/4
5/4
6/4
8/4
6/4
6/4
5/4
6/4
4/4
Volume
(in board feet)
6.5
12.9
17.4
26.0
20.0
18.8
14.3
13.4
5.4
Grade
Value
($)
1C
FAS
1C
1C
1C
1C
FAS
FAS
1C
4.00
12.77
14.09
21.73
16.26
15.21
15.54
15.31
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
Log 1
Log 2
Log 3
Log 5
Log 6
Log 7
Log 8
Live sawing
Sawmill
Optimization
Production
$92.35
$84.20
$94.97
$69.91
$118.22
$66.29
$100.48
$64.81
$74.25
$32.42
$45.23
$59.44
$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 years
Objectives:
1. Develop a $5-600,000 per unit CT log
scanner
2. Refine the optimization software
3. 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
Consumers
Increased
Profit
Strengthened
Global
Competitiveness
Enhanced
Resource
Conservation
Improved
Lumber
Quality