Source: NORTHEASTERN RESEARCH STATION submitted to NRP
NEED TO IDENTIFY AND EVALUATE OPPORTUNITIES FOR IMPROVING EFFICIENCY OF RESOURCE UTILIZATION
Sponsoring Institution
Forest Service/USDA
Project Status
COMPLETE
Funding Source
USDA INHOUSE
Reporting Frequency
Annual
Accession No.
0197437
Grant No.
(N/A)
Cumulative Award Amt.
(N/A)
Proposal No.
(N/A)
Multistate No.
(N/A)
Project Start Date
Jan 20, 1998
Project End Date
Jan 20, 2003
Grant Year
(N/A)
Program Code
[(N/A)]- (N/A)
Recipient Organization
NORTHEASTERN RESEARCH STATION
11 CAMPUS DRIVE
NEWTOWN SQUARE,PA 19073
Performing Department
FORESTRY SCIENCE LAB - PRINCETON, WV
Non Technical Summary
(N/A)
Animal Health Component
50%
Research Effort Categories
Basic
20%
Applied
50%
Developmental
30%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
1230613202075%
4020650301025%
Knowledge Area
123 - Management and Sustainability of Forest Resources; 402 - Engineering Systems and Equipment;

Subject Of Investigation
0650 - Wood and wood products; 0613 - Mixed conifer-broadleaf forests;

Field Of Science
2020 - Engineering; 3010 - Economics;
Goals / Objectives
To increase knowledge of tree, log, lumber, and product characteristics affecting wood utilization and to identify and evaluate opportunities for implementing technology and production control systems that increase product recovery and improve utilization of the hardwood resource.
Project Methods
Advanced process simulation software and optimization techniques will be developed to evaluate alternative processing systems and strategies for hardwood lumber rough mills and sawmills and to develop product recovery benchmarks for (1) specific mill types and (2) log or lumber inputs. Lumber and log scanning techniques will be applied to develop and expand the digitized log and lumber databases needed to reliably simulate wood processing systems and strategies. Research also will investigate opportunities for more efficient wood utilization through application of statistical process control methods that improve process predictability and product quality.

Progress 10/01/06 to 09/30/07

Outputs
OUTPUTS: A new version of the SOLVE program was developed that is compatible with today's software and operating environments, replete with help menus, and redesigned to be user friendly and flexible. The SOLVE program provides a sawmill analysis framework for determining operational efficiencies for different species, sizes, and qualities of logs. The key output provided by the program is a breakeven log price estimate that is based on lumber recovery data as well as sawing cost data (which can be derived using the COST program previously developed by the Princeton group). A searchable database of defect pictures for red oak and yellow-poplar logs that shows the external defect and the perpetuation of the defect on the lumber that is sawn from the log is an supplemental product derived from the unit's log scanning research. PARTICIPANTS: INDIVIDUALS INVOLVED: SOLVE: Mr. Jeff Palmer, Information Technology Specialist and Dr. Jan Wiedenbeck, Research Forest Products Technologist, USDA Forest Service, Northern Research Station, Princeton, WV. Defect Database: Mr. Ed Thomas, Computer Scientist, USDA Forest Service, Northern Research Station, Princeton, WV. TRAINING OPPORTUNITIES: The SOLVE program will be deployed through a series of training sessions in coordination with the Wood Education and Resource Center of State & Private Forestry and the State of Vermont.

Impacts
These software tools provide a means for evaluating log purchasing and processing decisions and can lead hardwood primary processors to procure those logs that are best suited for specific processing systems and markets so that efficiency and profit gains can be realized.

Publications

  • Murphy, Jamie A.; Smith, Paul M.; Wiedenbeck, Jan. 2007. Wood residue utilization in Pennsylvania: 1988 vs. 2003. Forest Products J. 57(4): 101-106.
  • Alderman, Delton; Brinberg, David; Nakamoto, Kent. 2006. Relationship building in technology and knowledge exchange: a paradigm for customized technology and knowledge discourse. [Abstract] In: Dobbertin, Michele Kaennel, ed. forestXchange: new approaches in knowledge management. International conference; 2006 October 25-27; Freiburg, Germany: 16.
  • Alderman, Delton; Nakamoto, Kent; Brinberg, David. 2007. From a social marketing perspective: a proposed customer relationship management technology transfer model. In: Miner, Cynthia; Jacobs, Ruth; Dykstra, Dennis; Bittner, Becky, eds. Proceedings, International Conference on Transfer of Forest Science Knowledge and Technology; 2005 May 10-13; Troutdale, OR. Gen Tech. Rep. PNW-GTR-726. Portland, OR. U.S. Department of Agriculture, Forest Service: 1-7.
  • Bond, Brian; Wiedenbeck, Jan. 2007. Does overlength impact drying quality and rough mill yield? Hardwood Matters: 4-6.
  • Bond, Brian; Wiedenbeck, Janice. 2006. Study of overlength on red oak lumber drying quality and rough mill yield. Forest Products J. 56(10): 15-19.
  • Buehlmann, Urs; Thomas, R. Edward. 2007. Relationship between lumber yield and board marker accuracy in rip-first rough mills. Holz als Roh- und Werkstoff 65: 43-48.
  • Michael, Judd H.; Evans, Demetrice D.; Jansen, Karen J,; Haight, Joel M. 2005. Management commitment to safety as organizational support: relationships with non-safety outcomes in wood manufacturing employees. Journal of Safety Research 36: 171-179.
  • Michael, Judd H.; Guo, ZhenGeorge; Wiedenbeck, Janice K.; Ray, Charles D. 2006. Production supervisor impacts on subordinates safety outcomes: an investigation of leader-member exchange and safety communication. Journal of Safety Research 37: 469-477.
  • Ray, Charles D.; Wiedenbeck, Janice K.; Pawar, Amit; Gill, Satinder. 2007. ROMI-flow: a combined process/flow modeling methodology for dimension hardwood mills. . In: 61st international convention of the Forest Products Society; 2007 June 10-13; Knoxville, TN. Madison, WI: Forest Products Society: 12. Abstract.
  • Smith, Robert L.; Duvall, Paul M.; Rappold, Patrick M.; Alderman, Delton R. 2007. White pine production and utilization in the Eastern United States. The Northern Logger & Timber Processor. February: 14-16.
  • Thomas, Ed; Buehlmann, Urs. 2007. Yield implications of global versus local process optimization in rip-first rough mills. Forest Products J. 57(3): 66-70.
  • Young, Timothy M.; Bond, Brian H.; Wiedenbeck, Janice K. 2007. Implementation of a real-time statistical process control system in hardwood sawmills. Forest Products J. 57(9): 54-62.
  • Wiedenbeck, Janice K. 2007. A forestry and product community committed to science and its application. In: 61st international convention of the Forest Products Society; 2007 June 10-13; Knoxville, TN. Madison, WI: Forest Products Society: 21. Abstract.


Progress 10/01/05 to 09/30/06

Outputs
The implementation of lean production methods can lead to gains in efficiency in wood processing operations; however, there is a lack of lean production metrics for the wood industry to use in benchmarking their implementation success. A methodology for quantitative and objective assessment of the leanness of any wood products operation has been developed. This "Lean Index" was used to assess the operations of nine wood products companies for which the average Lean Index was demonstrated to be 5.07, ranging from a low of 2.33 to a high of 12.00. Based on the quantified standards of lean production developed in this study, (1) primary wood products operations are inherently leaner than secondary wood products operations; (2) process throughput variables explain approximately twice the total variance of all consumed resources, compared to process support variables; and (3) energy consumption is shown to be the single most significant contributor to the leanness of any wood products company. Subsequently, a Rough Mill Flow simulator (ROMI-Flow) has been developed for research and decision support use. It is based on ROMI, AutoMod, and Microsoft Excel and Visual Basic programming tools. The user specifies the mill configuration and operational parameters through an Excel interface. ROMI-Flow can be used to design and test new plant layouts, plant modifications, or lean production kaizen events. The COST program was completed this year to assist sawmill operators in assessing their operating costs. The program is well suited for use in comparing the costs associated with different operating scenarios - a capability that can greatly improve the quality of operational decisions made by sawmill managers.

Impacts
The development of the Lean Index model moves us closer to a clear and logical definition of lean production for the wood products industry. The components of the Lean Index indicate that engineering improvements that reduce energy consumption may contribute the most to lean implementation by the wood products industry.

Publications

  • Alderman, Delton; Mu, Carolyn; Bowe, Scott A.; Smith, Robert L. 2006. Entrepreneurship-innovation in eastern white pine production and manufacturing. In: 60th international convention of the Forest Products Society; 2006 June 25-28; Newport Beach, CA. Madison, WI: Forest Products Society: 12. Abstract.
  • Alderman, Delton; Nakamoto, Kent; Brinberg, David. 2006. From a social marketing perspective: a proposed customer relationship management technology transfer model. In: International conference on transfer of forest science knowledge & technology; 2005 May 10-13; Troutdale, OR: [Place of publication unknown]:[Name of publisher unknown]: 11. Abstract.
  • Alderman, Delton; Nakamoto, Kent; Brinberg, David. 2006. Personalized technology transfer. In: 60th international convention of the Forest Products Society; 2006 June 25-28; Newport Beach, CA. Madison, WI: Forest Products Society: 10. Abstract.
  • Beakler, Brian W. 2006. Environmental burden from kiln drying hardwood lumber. University Park, PA: Pennsylvania State University. 270 p. Ph.D. dissertation.
  • Beakler, Brian W.; Blankenhorn, Paul R.; Brown, Nicole R.; Wiedenbeck, Janice K. 2006. Quantification of the volatile organic compounds (VOCs) from kiln-drying hardwood lumber. In: 60th international convention of the Forest Products Society; 2006 June 25-28; Newport Beach, CA. Madison, WI: Forest Products Society: 26. Abstract.
  • Bond, Brian H.; Ese-Etame, Roncs; Wiedenbeck, Janice K. 2006. The effect of ellipticality on processing of red oak logs. 2006. In: 60th international convention of the Forest Products Society; 2006 June 25-28; Newport Beach, CA. Madison, WI: Forest Products Society: 26. Abstract.
  • Ese-Etame, Roncs. 2006. Impact of ellipticality on lumber grade and volume recovery for red oak logs. Blacksburg, VA: Virginia Polytechnic Institute and State University. 107 p. M.S. thesis.
  • Palmer, Jr., A. Jefferson; Wiedenbeck, Janice K.; Mayer, Robert W. 2005. Cost of sawing timber (COST) module (Version 1.0) for windows [computer program]. Gen. Tech. Rep. NE-338. Newtown Square, PA: U.S. Department of Agriculture, Forest Service, Northeastern Research Station. 18 p.
  • Pickens, James B.; Noble, Scott; Orr, Blair; Araman, Philip A.; Baumgras, John E.; Steele, Al. 2006. HW buck for windows: the optimal hardwood log bucking decision simulator with expanded capabilities. In: Proceedings, Society of American Foresters 2005 national convention; 2005 October 19-23; Fort Worth, TX. Bethesda, MD: Society of American Foresters: 7.
  • Ray, Charles D.; Zuo, Xiaoqiu; Michael, Judd H.; Wiedenbeck, Janice K. 2006. The lean index: operational lean metrics for the wood products industry. Wood and Fiber Science. 38(2):238-255.
  • Pickens, James B.; Everett, Aaron; Noble, Scott; Baumgras, John; Araman, Philip; Waniger, Conrad; Steele, Al. 2006. Intensive hardwood log bucker training using HW buck dramatically improves value recovery. In: Proceedings, Society of American Foresters 2005 national convention; 2005 October 19-23; Fort Worth, TX. Bethesda, MD: Society of American Foresters: 9.
  • Scholl, Matthew S.; Blankenhorn, Paul R.; Ray, Charles D.; Wiedenbeck, Janice K. 2006. Sawing and drying of hardwood lumber from small-diameter logs. In: 60th international convention of the Forest Products Society; 2006 June 25-28; Newport Beach, CA. Madison, WI: Forest Products Society: 26. Abstract.
  • Thomas, Edward; Weiss, Joel. 2006. Rough mill simulator version 3.0: an analysis tool for refining rough mill operations. Forest Products Journal. 56(5):53-58.
  • Wiedenbeck, Jan; Palmer, Jeff; Mayer, Robert. 2006. Make log yield analysis part of your daily routine. Hardwood Matters. February: 8-9, 11.


Progress 10/01/04 to 09/30/05

Outputs
Using the mix of lumber grades that minimizes the cost of producing dimension parts has been of interest to industry and technology developers for decades. Many tools and procedures for finding the least-cost lumber mix assume that a linear relationship exists between lumber grade mix and product yield. This assumption did not hold true in more than half the cases examined in a comprehensive study completed this year. A least-cost lumber grade mix approach that uses predictions of the optimal grade mix based on the recently completed ROMI-3 simulation program will provide better results. The ROMI-3 lumber cut-up simulation program including associated programs for least cost lumber grade mix prediction and optimal saw spacing setup combined with the just completed Rough Mill Improvement Guide for Managers and Supervisors provides a complete package of rough mill efficiency tools for the value-added wood products industry. The rate of occurrence of safety incidents in wood products manufacturing are among the highest for all U.S. manufacturing industries. Many wood products manufacturers place strong emphasis on production to fulfill orders and meet quotas. Companies that place a particularly strong emphasis on mill production levels experience an increase in safety-related incidents while companies that have a stronger safety climate/focus experience a reduced rate of incidents. A climate that balances productivity, quality, and safety needs to be established and supported by management.

Impacts
The value of decision-making tools to industrial users depends on the degree to which the tools are found to be reliable, efficient, understandable, and user friendly. By meeting these criteria, the rough mill analysis tools provided in 2005 will lead companies with limited analysis resources to gain insight into the impacts that operational changes may have on processing efficiency and cost competitiveness. Used as training materials, these products can provide for a more highly trained workforce that understands the impact they can have on achieving company goals.

Publications

  • Wiedenbeck, Janice K.; Blankenhorn Paul R.; Scholl, Matthew; Stover, Lee R. 2003. Small-diameter hardwood utilization with emphasis on higher value products. In: Moore, Susan; Bardon, Robert, eds. Enhancing the southern Appalachian symposium proceedings; 2003 October 2-3; Hendersonville, NC. Raleigh, NC: North Carolina State University, Forestry Educational Outreach Program. [CD-ROM].
  • Wiedenbeck, Janice K.; Buehlmann, Urs; Morales, Lucia. 2005. Marketing plan for solid wood panels from American hardwoods. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 42. Abstract.
  • Wiedenbeck, Jan; Shepley, Brian P.; Smith, Robert L. 2004. Rough-mill yield and cutting efficiency for No. 3A Common lumber compared to other lumber grade mix options. Forest Products Journal. 54(12): 132-140.
  • Zuo, Xiaoqiu; Buehlmann, Urs; Thomas, R. Edward. 2004. Investigating the linearity assumption between lumber grade mix and yield using design of experiments (DOE). Wood and Fiber Science. 36(4): 547-559.
  • Zuo, Xiaoqiu; Buehlmann, Urs; Wiedenbeck, Janice K. 2005. Investigating the effects of lumber quantity on ROMI-RIP 3.0 yield results. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 45. Abstract.
  • Thomas, Edward. 2005. Predicting internal defects from examining exterior features: an analysis of yellow-poplar defects. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 6. Abstract.
  • Thomas, Edward; Liya, Huang, Yi-yang, Shan, Maoda, Lou. 2004. Brief discussion about relation between Java and automatic control and production safety of wood processing industry. Forestry Labor Safety. 17(3):21-27.
  • Thomas, Liya; Mili, Lamine; Shaffer, Clifford A.; Thomas, Ed. 2004. Defect detection on hardwood logs using high resolution three-dimensional laser scan data. In: IEEE international conference on image processing (ICIP); 2004 October 24-27; Singapore. [Place of publication unknown]: Institute of Electrical and Electronics Engineers: 243-246. Thomas, Liya; Thomas, Edward; Mili, Lamine; Schaffer, Clifford. 2005. Locating exterior defects on hardwood logs using high resolution laser scanning. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 7. Abstract.
  • Wang, Xiping; Ross, Robert J.; Wiedenbeck, Janice K.; Forsman, John W.; Erickson, John R.; Pilon, Crystal; Brashaw, Brian K. 2005. Incipient decay detection in hardwood logs. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 48. Abstract.
  • Weiss, Joel M.; Thomas, R. Edward. 2005. ROMI-3: Rough-Mill Simulator Version 3.0: users guide. Gen. Tech. Rep. NE-328. Newtown Square, PA: U.S. Department of Agriculture, Forest Service, Northeastern Research Station. 75 p.
  • Wiedenbeck, Janice K. 2005. Vertically integrated companies in the hardwood industry, does this strategy make sense in today's environment? In: Manufacturing competitiveness of the forest products industry: competing in today's global manufacturing and consumer marketplace; 2004 November 3-5; New Orleans, LA: Madison, WI: Forest Products Society: 14. Abstract.
  • Zuo, Xiaoqiu; Wiedenbeck, Janice K.; Ray, Charles D.; Michael, Judd H. 2005. Transferring integrated manufacturing to integrated supply chain for the hardwood products industry. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 10. Abstract.
  • Thomas, Edward. 2005. Global versus local optimization, impact on rough mill yield. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 22. Abstract.
  • Deaver, Maurice E.; Buehlmann, Urs; Wiedenbeck, Janice K. 2005. Feasibility of solid hardwood panel manufacturing enterprise. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 9. Abstract.
  • Duvall, Paul Mason. 2004. Assessing eastern white pine lumber production and use in the eastern United States. Blacksburg, VA: Virginia Polytechnic Institute & State University. 211 p. M.S. thesis.
  • Evans, Demetrice D. 2004. An investigation of individual and organizational factors influencing employee safety performance in the wood products industry. University Park, PA: The Pennsylvania State University. 124 p. M.S. thesis.
  • Evans, Demetrice D.; Michael, Judd H.; Wiedenbeck, Janice K.; Ray, Charles D. 2005. Relationships between organizational climates and safety-related events at four wood manufacturers. Forest Products Journal. 55(6): 23-28.
  • Mayer, Robert; Wiedenbeck, Jan. 2005. Continuous sawmill studies: protocols, practices, and profits. Gen. Tech. Rep. NE-334. Newtown Square, PA: U.S. Department of Agriculture, Forest Service, Northeastern Research Station. 32 p.
  • Michael, Judd H.; Wiedenbeck, Janice K. 2004. Safety in the wood products industry. Forest Products Journal. 54(10): 8-18.
  • Mitchell, Philip H.; Wiedenbeck, Jan; Ammerman, Bobby. 2005. Rough mill improvement guide for managers and supervisors. Gen. Tech. Rep. NE-329. Newtown Square, PA: U.S. Department of Agriculture, Forest Service, Northeastern Research Station. 60 p.
  • Rappold, Patrick M.; Kline, D. Earl; Bond, Brian H.; Wiedenbeck, Janice K. 2005. Measuring the grade and volume of lumber produced at the log breakdown machine centers in a hardwood sawmill: what can it tell us about manufacturing efficiency? In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 8. Abstract.
  • Roncs, Ese Etame; Bond, Brian H.; Smith, Robert L.; Wiedenbeck, Janice K. 2005. The impact of log eccentricity on red oak (Quercus rubra) lumber grade and volume recovery for current sawing practices. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 46. Abstract.
  • Zuo, Xiaoqiu; Ray, Charles D.; Wiedenbeck, Janice K. 2005. Analysis on push and pull systems in rough mills. In: Forest Products Society 59th international convention; 2005 June 19-22; Quebec City, PQ. Madison, WI: Forest Products Society: 45. Abstract.


Progress 10/01/02 to 09/30/03

Outputs
A sample of 162 red oak and yellow-poplar logs was scanned using a high-resolution laser profile scanner. This data is now being digitally rendered and interpreted for the detection of surface defects. A related study is examining hardwood log defect cross sections to collect data for a model capable of predicting internal defect characteristics based on external indicators. It is planned that these research programs will result in an external scanner that can infer internal defect characteristics (a very affordable technology). Final revisions to the ROMI-3 software program, a tool that enables the value-added wood products industry and researchers to evaluate alternative raw material, processing, and product options, have been completed. The program is being rigorously tested by a group of users. The best features of the ROMI-RIP and ROMI-CROSS programs along with many new features have been combined in this ultimate edition of the program. One new feature helps users determine optimal saw spacings for their rip saw(s) to reduce wood waste. A study to determine expected component part yields when cutting low-grade (3A Common) lumber was completed. Relative processing efficiencies were evaluated for this lumber grade compared to other lumber grades. Cutting efficiencies for 3A Common lumber were 10 to 20 percent lower and product yields were 12 to 20 percent below those obtained from the next higher lumber grade. Price differentials required for the low-grade lumber to be economically viable as a substitute raw material were estimated. The costs and benefits associated with precision-end trimming hardwood lumber have been studied both in the processing plant and in simulations. The question being addressed is whether precisely trimming hardwood lumber in the sawmill has a net positive or negative effect on yield and processing costs in further processing operations. Yield tests indicate untrimmed lumber, if handled and dried carefully, can produce part yields that are 1.5 to 2.0 percent higher than for precision trimmed lumber. However, when the lumber is air dried before entering the kiln, the potential yield gain is not realized.

Impacts
With information on the internal characteristics of defects based on external identification via laser scans, the value of lumber recovered in sawmilling may be increased by more than 10 percent. Use of the costing program will improve lumber manufacturing cost estimates for sawmill users. This will enable these mills to make better decisions as to which species, grades, and sizes of logs they may process profitably and which they should either not buy or resell after purchase. Lumber grade decisions have an enormous influence on profitability in the rough mill where lumber is converted into component parts. Yet there is a wide variation in the part sizes and grades of parts that are cut making this decision very complex. Many value-added hardwood product manufacturers are looking to reduce raw material costs. Increased use of the least expensive lumber grade, 3A Common, is one strategy being pursued. The low-grade lumber study results reveal feasible situations for utilizing 3A Common lumber. The upgraded rough mill simulation software is a tool that helps rough mills make both short and longer term decisions that will yield the most cost efficient production strategies. A 1 percent yield improvement in rough mill processing translates to an average annual profit improvement of $300,000; these tools lead to improvements of this magnitude. With domestic furniture production off more than 30 percent over the last 3 years due to plant closures resulting from loss of markets to imports, these products are timely and highly demanded.

Publications

  • Zuo, Xiaoqiu; Buehlmann, Urs; Thomas, R. Edward. 2003. Lumber cost minimization through optimum grade-mix selection. In: Deisenroth, Michael P., ed. Enterprise integration a production perspective: 17th international conference on production research; 2003 August 3-7; Blacksburg, VA. Blacksburg, VA: Virginia Polytechnic Institute and State University. CD-ROM.
  • Thomas, R. Edward; Buehlmann, Urs. 2003. The potential of computer controlled optimizing equipment in the wooden furniture industry. In: Deisenroth, Michael P., ed. Enterprise integration a production perspective, 17th international conference on production research; 2003 August 3-7; Blacksburg, VA. Blacksburg, VA: Virginia Polytechnic Institute and State University. CD-ROM.
  • Wiedenbeck, Jan. 2002. Effect of vertical integration on the utilization of hardwood resources. In: Smalley, Bryan, ed. Current topics in the processing and utilization of hardwood lumber: proceedings of the 30th annual hardwood symposium; 2002 May 30-June 1; Memphis, TN. Memphis, TN: National Hardwood Lumber Association: 144-146.
  • Wiedenbeck, Jan. 2003. Expertise in primary and secondary solid-wood processing. NE-INF-157-02. Newtown Square, PA: U.S. Department of Agriculture, Forest Service, Northeastern Research Station. 18 p.
  • Wiedenbeck, Jan; Blackwell, Kyle. 2003. Hardwood sawmill downtime costs. Southern Lumberman. 264(5): 27-31.
  • Wiedenbeck, Jan; Brown, John; Bennett, Neal. 2003. Crook and overlength in hardwood lumber: results from a 14-mill survey. Forest Products Journal. 53(5): 61-66.
  • Wiedenbeck, Jan; Brown, John; Bennett, Neal; Rast, Everette. 2003. Hardwood lumber widths and grades used by the furniture and cabinet industries: results of a 14-mill survey. Forest Products Journal. 53(4): 72-80.
  • Young, Timothy M.; Bond, Brian H.; Wiedenbeck, Jan. 2002. Reducing lumber thickness variation using real-time statistical process control. In: Smalley, Bryan, ed. Current topics in the processing and utilization of hardwood lumber: proceedings of the 30th annual hardwood symposium; 2002 May 30-June 1; Memphis, TN. Memphis, TN: National Hardwood Lumber Association: 103-113.
  • Gazo, Rado; McGlothlin, James D.; Yih, Yuehwern; Wiedenbeck, Jan. 2002. Ergonomics and safety in secondary wood processing. In: Smalley, Bryan, ed. Current topics in the processing and utilization of hardwood lumber, proceedings of the 30th annual hardwood symposium; 2002 May 30-June 1; Memphis, TN. Memphis, TN: National Hardwood Lumber Association: 114-121.
  • Rappold, Patrick M.; Kline, D. Earl; Bond, Brian H.; Wiedenbeck, Janice K. 2003. Determining hardwood sawmill efficiency factors. In: Forest Products Society 57th annual meeting; 2003 June 22-25; Bellevue, WA. Madison, WI: Forest Products Society: 43. Abstract.
  • Shepley, Brian Patrick. 2002. Simulating optimal part yield from No. 3A Common lumber. Blacksburg, VA: Virginia Polytechnic Institute and State University. 138 p. M.S. thesis.
  • Thomas, Ed; Thomas, Liya; Mili, Larmine; Ehrich, Roger; Abbott, A. Lynn; Shaffer, Clifford. 2003. Primary detection of hardwood log defects using laser surface scanning. In: Proceedings, International Society for Optical Engineering; 2003 January 22-24; Santa Clara, CA. SPIE (5011): 39-49.
  • Thomas, R. Edward; Brown, John. 2003. Determining the impact of sorting capacity on rip-first rough mill yield. Forest Products Journal. 53(7/8): 54-60.
  • Thomas, R. Edward; Buehlmann, Urs. 2003. Lumber yield implications of board marker decisions. In: Forest Products Society 57th annual meeting; 2003 June 22-25; Bellevue, WA. Madison, WI: Forest Products Society: 10. Abstract.
  • Thomas, R. Edward; Buehlmann, Urs. 2003. Performance review of the ROMI-RIP rough mill simulator. Forest Products Journal. 53(3): 80-85.
  • Bond, Brian H. 2002. Increasing yield of hardwood lumber through precision end trimming. In: Forest Products Society quality drying: the key to profitable manufacturing; 2002 September 23-25; Montreal, PQ. Madison, WI: Forest Products Society: 10. Abstract.
  • Bond, Brian H.; Wiedenbeck, Janice K. 2003. The effect of over-length on rough mill yield. In: Forest Products Society 57th annual meeting; 2003 June 22-25; Bellevue, WA. Madison, WI: Forest Products Society: 11. Abstract.
  • Buehlmann, Urs; Thomas, R. Edward. 2003. Impact of board-marker accuracy on lumber yield. In: Ahmad, Munir; Miller, William; Yalcin, Ali, eds. Proceedings, 13th international conference on flexible automation & intelligent manufacturing; 2003 June 9-11; Tampa, FL. [Place of publication unknown]: [Publisher name unknown]: 278-287.
  • Buehlmann, Urs; Wiedenbeck, Janice K.; Kline, D. Earl. 2003. Effect of cutting bill on lumber yield in a rip-first rough mill. Wood and Fiber Science. 35(2): 187-200.


Progress 01/20/98 to 01/20/03

Outputs
OUTPUTS: A new version of the SOLVE program was developed that is compatible with today's software and operating environments, replete with help menus, and redesigned to be user friendly and flexible. The SOLVE program provides a sawmill analysis framework for determining operational efficiencies for different species, sizes, and qualities of logs. The key output provided by the program is a breakeven log price estimate that is based on lumber recovery data as well as sawing cost data (which can be derived using the COST program previously developed by the Princeton group). A searchable database of defect pictures for red oak and yellow-poplar logs that shows the external defect and the perpetuation of the defect on the lumber that is sawn from the log is a supplemental product derived from the unit's log scanning research. PARTICIPANTS: INDIVIDUALS INVOLVED: SOLVE: Mr. Jeff Palmer, Information Technology Specialist and Dr. Jan Wiedenbeck, Research Forest Products Technologist, USDA Forest Service, Northern Research Station, Princeton, WV. Defect Database: Mr. Ed Thomas, Computer Scientist, USDA Forest Service, Northern Research Station, Princeton, WV. TARGET AUDIENCES: Managers of forest product businesses, consultants, State extension personnel. PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
These software tools provide a means for evaluating log purchasing and processing decisions and can lead hardwood primary processors to procure those logs that are best suited for specific processing systems and markets so that efficiency and profit gains can be realized. One hundred and eighty one copies of the SOLVE and COST programs were downloaded from the Princeton web site over the last 12 months - 63 percent of customers were from the U.S. with downloads going to customers in 23 countries.

Publications

  • Wiedenbeck, Janice K.; Palmer, Jeff; Mace, Terry R. 2008. Decision-support tools for assessing options in processing small logs. In: Small Wood, 2008 May 13-15; Madison, WI: Forest Products Society; Biomass Energy Resource Center; Marth Wood Supply, Inc. and Pellet Fuels Institute; and U.S. Department of Interior: 19. Abstract.
  • Buehlmann, Urs; Kline, D. Earl; Wiedenbeck, Janice K.; Noble, Jr., R. 2008. Validation of the standardized and simplified cutting bill. Wood and Fiber Science 40(2): 202-213.
  • Buehlmann, Urs; Wiedenbeck, Janice K.; Noble, Jr., R.; Kline, D. Earl. 2008. Creating a standardized and simplified cutting bill using group technology. Wood and Fiber Science 40(1): 29-41.
  • Buehlmann, Urs; Zuo, Xiaoqiu; Thomas, R. Edward. 2008. Performance evaluation of the least-cost lumber grade-mix solver. Wood and Fiber Science 40(3): 427-435.


Progress 10/01/01 to 09/30/02

Outputs
A project comparing lumber recovery rates and processing efficiencies associated with a range of sawmilling equipment and hardwood log inputs showed that sawmills that use band saws in the first stage of log breakdown produce 18 percent more lumber per cubic foot of log input than sawmills that use circular saws. Furthermore, band sawmills were more reliable having downtime rates of about 10 percent compared to 17 to 19 percent for circle sawmills. Research projects were completed that examined how the yield of solid wood furniture and cabinet parts cut from hardwood lumber is affected by the human decision making process and the size of the input raw material. Results from one project indicate that human error in marking hardwood lumber strips for cut-up into parts can reduce part yields by 16 percent. The major type of error observed was the failure of the operator to recognize and mark existing defects on the lumber strips. Another important class of errors encountered was poor placement of the marks such that some portion of the defective wood section was not eliminated from the product. The part rejection rate resulting from these errors in judgment led to rejection of 22 percent of the parts. Lumber scanning coupled with lumber cut-up optimization software will have a payback period of less than 1 year in an average-size lumber cut-up operation even if the automated system performs only 50 percent better than the operator. In the second yield project, it was shown that lumber length has a direct effect on furniture and cabinet part yields with longer lumber (15 to 16 ft.) consistently producing part yields about 5 percent higher than the shortest lumber group (7 to 8 ft.) and intermediate length lumber (11 to12 ft.) consistently produced intermediate part yields. These are large and meaningful yield differences. With lumber costs constituting about 50 percent of the cost of sales in lumber cut-up (or rough mill) operations, a large investment in mill equipment to improve the mill's lumber sorting and inventory control can be easily justified.

Impacts
Since raw material costs constitute approximately 50 percent of total manufacturing costs in lumber processing and furniture parts processing operations, increases in product recovery rates have substantial dollar impacts on total manufacturing costs. For a mid- to large-size sawmill, the annual reduction in raw material expenses associated with the 18 percent increase in recovery generates an annual cost savings of $500,000 to $1,000,000. For a mid- to large-size lumber cut-up operation, the annual reduction in raw material expenses associated with a 16 percent increase in product yield is conservatively estimated at $1,600,000.

Publications

  • Zuo, Xiaoqiu; Buehlmann, Urs; Thomas, R. Edward. 2002. Applying a mixture design to solve the least cost grade mix problem. In: Forest Products Society 56th annual meeting; 2002 June 23-26; Madison, WI. Madison, WI: Forest Products Society: 43. Abstract.
  • Blackwell, Kyle A. 2000. Hardwood sawmill performance comparison. Lexington, KY: University of Kentucky. 131 p. M.S. thesis.
  • Buehlmann, U.; Thomas, R.E. 2001. The impact of human error when marking lumber in furniture rough mills. In: El-Baradie, Mohie; Szecsi, Tamas: 11th international conference on flexible automation and intelligent manufacturing; 2001 July 16-18; Dublin, Ireland. Dublin, Ireland: Dublin City University: 653-666.
  • Buehlmann, Urs; Kline, D. Earl; Wiedenbeck, Janice K. 2002. Yield response surface: a comprehensive investigation of the yield-cutting bill part size relationship. In: Forest Products Society 56th annual meeting; 2002 June 23-26; Madison, WI. Madison, WI: Forest Products Society: 9-10. Abstract.
  • Buehlmann, Urs; Thomas, R. Edward. 2002. Impact of human error on lumber yield in rough mills. Robotics and Computer Integrated Manufacturing. 18: 197-203
  • Hamner, Peter C.; Bond, Brian H.; Wiedenbeck, Janice K. 2002. The effects of lumber length on part yields in gang-rip-first rough mills. Forest Products Journal. 52(5): 71-76.
  • Maoda, Lou; Thomas, Ed. 2002. The status and future of applying computer technology in the international wood processing industry. International Wood Industry. 1: 12-15.
  • Shelpley, Brian; Smith, Robert L.; Wiedenbeck, Janice K. 2002. Simulating optimal part yield from 3A Common lumber. In: Forest Products Society 56th annual meeting; 2002 June 23-26; Madison, WI. Madison, WI: Forest Products Society: 42. Abstract.
  • Thomas, Edward R.; Buehlmann, Urs. 2002. Validation of the ROMI-RIP rough mill simulator. Forest Products Journal. 52(2): 23-29.
  • Wiedenbeck, Janice K.; Brown, John. 2002. Sample size requirements for hardwood sawmill studies indicate a new mill study approach must be utilized. In: Forest Products Society 56th annual meeting; 2002 June 23-26; Madison, WI: Forest Products Society: 8. Abstract.
  • Young, Timothy M.; Bond, Brian H. 2002. Reducing lumber thickness variation using real-time statistical process control - a case study at Anderson-Tully Corporation. In: Forest Products Society 56th annual meeting; 2002 June 23-26; Madison, WI. Madison, WI: Forest Products Society: 14. Abstract.