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Prawda achieves financial gains by upgrading production processes After investing in an optimizing Opti-Kap 5103 cross-cut line, Prawda profited from a reduction of manpower and an increase in wood utilization, uniformity of production, and production uptime. Read the full story on page 2.
no. 1 - 2019
Leading Danish Company Chooses System TM for These 3 Reasons Read the full story on page 6.
System TM to Showcase Full Range of Machinery in Action at LIGNA 2019 At this year’s LIGNA, System TM’s booth will be brimming with cutting edge technologies and machine-to-machine integration, as we showcase an Opti-Solution manufacturing line in full operation. Read the full story on page 4 & 5.
Why industry experience matters: Hassell & Hughes invests in System TM solution System TM’s many years of experience in the North American hardwood flooring industry is the very reason why Hassell & Hughes recently opted for an Opti-Kap 5103 cross-cut line with a special feature. Read the full story on page 7.
optimization of staff and wood resources
Bedside tables by Prawda q
A Change for the Better: Prawda Achieves Financial Gains by Upgrading Production Processes As the need to improve and future-proof its production grew bigger and bigger, Prawda recognized that its production processes had to undergo some modifications. After investing in an optimizing Opti-Kap 5103 cross-cut line, Prawda profited from a reduction of manpower and an increase in wood utilization, uniformity of production, and production uptime.
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Maciej Ogonowski, Manufacturing Director of Prawda:
‘‘This is the second crosscut line that System TM delivers. Our experience with the lines’ optimization of pine and birch lamellas is phenomenal. The whole process of deciding on a new line, the timeliness of delivery and the process of assembly and start-up was all at the highest possible level of professionalism. I hope everyone gets a chance to collaborate with a provider like System TM.’’
From stuffed toys and cushions to plywood Prawda was established in Olecko, eastern Poland, in 1989. In its earliest days, the company manufactured soft toys and cushions, but new opportunities arose in the 1990’s due to dynamic changes in the market. In 1997, Prawda decided to change its product portfolio from stuffed toys and cushions production to plywood production. It didn’t take long for Prawda to expand worldwide and in 2001, Prawda built a new manufacturing facility and specialized in the production of wooden cabinet and frame furniture (pine and birch). At the forefront of innovation Innovative wood processing characterizes Prawda’s manufacturing processes and helps the company achieve optimal use of raw wood material. Prawda continuously strives to build a strong global position as a manufacturer of products with high quality and reliability. A change for the better Although Prawda was overly pleased with the yield and performance of its existing System TM cross-cut line for pine wood production, the need to enhance and future-proof its birch wood production was growing bigger and bigger. Eventually, Prawda decided to contact System TM to work out yet another cross-cut solution; this time for birch wood production.
How to stand out against competitors According to Manufacturing Director of Prawda, Maciej Ogonowski, Prawda’s expectations for this cross-cut line were met by System TM due to several reasons. ‘‘The System TM line stood out against competitors due to its stability, simplicity and high-performance machinery which we were confident would provide us high uptime’’, says Maciej Ogonowski. ‘‘We truly appreciate the flexibility exhibited by System TM in the design phase and the company’s eagerness to match all our requirements. Also, System TM was fully compliant with the project’s time schedule and dealt with unforeseen things during the commissioning phase in such a way that both of our interests were kept in mind’’, he adds. The earnings from choosing a System TM line Some of the marked improvements Prawda gained from upgrading its production processes include: a reduction of machine operators to bring down labor costs, an increased wood utilization due to the scanner and optimization software in the line, a better uniformity of production, and an increased production uptime. ‘‘We are truly satisfied with the optimizing Opti-Kap 5103 cross-cut line. Indeed, we received what we ordered and a little more – higher performance parameters than originally contracted’’, says Maciej Ogonowski.
Production optimization to the highest degree The Opti-Kap 5103 cross-cut line is designed with a special feed system that handles stackedin-racks lamellas. After unloading the racks, the birch lamellas are led through a separator. The separator separates them for manual inspection before they enter a MiCROTEC Goldeneye 502+ scanner featuring an X-ray unit where defects and grain patterns are identified. Then, the scanner data is transferred to an optimizing software program that calculates the best cutting position. This data is used by two Opti-Kap 5103 cross-cut saws that follow. As workpieces enter the Opti-Kap 5103 crosscut saws, the optimizing software program instructs the cross-cut saws how to cut workpieces with maximum wood utilization. Workpieces exit the cross-cut saws onto two sorting belt conveyors where they are sorted into two classifications: finger jointing blocks or long fixed lengths. Then, workpieces are distributed according to their various lengths and qualities into sorting boxes in the above-mentioned classifications. Once a sufficient number of workpieces is reached, the sorting boxes are emptied. Fixed lengths can be stacked manually from several sorting tables. Finally, large batch productions of workpieces are stacked by two optimizing OptiStack 3000 stackers.
OPTI-STACK 3000 Automated stacking system
OPTI-KAP 5103
Optimizing cross-cut saws
MICROTEC M3 SCAN Moisture measurement
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This System TM solution consists of the following: An automated feeding system, Opti-
MICROTEC GOLDENEYE 502 SCANNER
Feed 6000 •
Detection of defects and quality before cross-cutting
A MiCROTEC Goldeneye 502 scanner with X-Ray
•
OPTI-FEED 6000
A MiCROTEC M3 Scan for moisture
• •
Automated feeding system
Overview:
measurement Two optimizing cross-cut saws, Opti-
Production:
Furniture Components
Kap 5103
Wood species: Hardwood
An automated stacking system, Opti-
Number of operators:
Stack 3000
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The Power of Brand Promise: Why It Pays to Be True to Your Word In a time where customer experience is one of the best sources of competitive differentiation, Produits Matra’s customer experiences with System TM have been highly successful due to System TM’s ability to deliver on its production capacity promise time after time. Today, Produits Matra enjoys 33% increase in production capacity thanks to its new System TM line, an optimizing Opti-Joint H-200 finger-jointing line. We’ve all felt the sting of a broken promise before. In the business world, a broken brand promise can be enough to damage an entire organization. But when a brand follows through on its promise, the result is a loyal and happy customer base. In order to deliver on your promise, words must always conform to reality. This was the case in the Produits Matra project, as the production capacity promise that was made by System TM at the beginning of the project conforms to the reality of the running finger-jointing line at Produits Matra in Quebec, Canada. According to Produits Matra, System TM is a company true to its word due to its accuracy and punctuality in developing an Opti-Joint H-200 finger-jointing line that produces 200 blocks per minute or, in other words, a 33% production capacity increase. Surviving and thriving after a fire Founded in 2000 by two brothers Nicholas & Jean-Francois Drouin in Saint-Martin-de-Beauce, Canada, Produits Matra manufactures quality door and window components, as well as primed siding and trim from Eastern White Pine. Tragically, the company’s factory was destroyed by a fire in 2010. With the help of employees, a new and three times more efficient factory rose
from the ashes less than eight months later, fitted with state-of-the-art manufacturing equipment, including a System TM cross-cut line. This was Produits Matra’s first investment in System TM equipment, which marked the beginning of a prosperous relationship between the two companies – one that has turned Produits Matra into a repeat customer at System TM. Today’s status Today, Produits Matra has three cutting-edge factories, 175 employees, and over 170,000 sq. ft. of production space. The company is also a key player in the transformation of Eastern White Pine on the Canadian and U.S. market. In the years ahead, Matra intends to continue to enhance both the quality of its products and the performance of its factories, and pursue its ongoing efforts to lead the industry for the benefit of customers and for the generations to come. Gaining a 33% production capacity boost To enhance production capacity and product output, Produits Matra decided to add more Sysstem TM machinery to one of its factories by investing in a finger-jointing line featuring a horizontal finger jointer, the Opti-Joint H-200. With a sales process that finished in record-time, the finger-jointing line was up and running in no time. ‘‘The finger-jointing line now opti-
mizes Produits Matra’s production processes by reducing its number of operators to a great extent and boosting production capacity by 33%. In block numbers, this is an increase from 150 blocks to 200 blocks per minute’’, says Jean-Luc Croteau, Area Sales Manager for North America at System TM.
Finger-jointed products by Produits Matra q
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At first, workpieces are fed into the fingerjointing line using an Opti-Feed spin feeder with index feeding. Then, workpieces are fingerjointed by the Opti-Joint H-200 horizontal finger jointer, which processes 200 workpieces/ minute. Once the horizontal finger jointing process is complete, workpieces are stacked by a stacker, packed and transported to subsequent processes. What makes the Opti-Joint H-200 unique? The Opti-Joint H-200 is a heavy-duty horizontal finger jointing machine designed with high-quality mechanical and electrical components. The Opti-Joint H-200 provides exceptionally high production capacity of softwoods and hardwoods and ensures high jointing precision and quality. Workpieces move very quickly, accurately and securely during the finger-jointing process of an Opti-Joint H-200. As a result, this ensures maximum performance, productivity and quality, and keeps downtime to a minimum.
Jean-Luc Croteau, Area Sales Manager for North America at System TM:
‘‘The Opti-Joint H-200 finger-jointing line optimizes Produits Matra’s production processes by reducing the number of operators and boosting production capacity by 33%. In block numbers, this is an increase from 150 blocks to 200 blocks per minute.’’
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This System TM solution consists of the following: •
Automatic workpiece alignment, OptiFeed spinfeeder
OPTI-FEED H-200 Feeding unit
•
A feeding unit, Opti-Feed H-200
•
A horizontal finger-jointer, Opti-Joint H-200
OPTI-JOINT H-200
Horizontal finger jointing machine
OPTI-FEED SPINFEEDER Automatic workpiece alignment
Overview: Production:
Windows & Doors, Moulding
Wood species: Softwood Number of operators:
q
Produits Matra’s head office in Saint-Martin, Quebec
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System TM to Show Machinery in Actio
At this year’s LIGNA, System TM’s booth will b machine-to-machine integration. An Opti-Soluti operation with an array o ► Opti-View system – a data collection system: • Collects and analyzes performance data from each machine unit, allowing users to analyze crucial data from their line in order to adjust their line and achieve best overall equipment performance.
► Opti-Solution – a fully automatic solution: • System TM Opti-Feed 6000 Vack automated infeed system • MiCROTEC Viscan for strength measurement of workpieces • MiCROTEC Curvescan for twist, bow, cup, spring and crook measurement of workpieces • MiCROTEC Opti-Side for annual ring orientation and pith detection • MiCROTEC M3 Scan moisture meter • MiCROTEC Goldeneye 502 scanner including X-ray • System TM Opti-Kap 5103 optimizing cross-cut saws (2) • System TM Opti-Stack 3000 automated stacking system • System TM automatic batch creating system for vertical finger jointing
► One scanner, one a standard solution
• MiCROTEC Goldeneye 30
• System TM Opti-Kap 510
We look forward to seeing you at LIGNA
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wcase Full Range of on at LIGNA 2019
be brimming with cutting edge technologies and ion manufacturing line will be showcased in full of machines and options. ► Experience the full range of System TM machinery • Come join us, as we showcase an Opti-Solution manufacturing line in full operation with an array of machines and options from both System TM and MiCROTEC. • System TM will be presenting powerful machinery designed with high artificial intelligence (Industry 4.0), less need for human intervention to minimize human error, and more self-regulation to uphold the highest levels of manufacturing efficiency and uptime.
saw solution – n:
02 scanner
03 optimizing cross-cut saw
For free e-tickets, please use the following link or corresponding QR Code: www.ligna.de/ticketregistration?6ckf2
A 2019. Visit us in Hall 27, Stand D28.
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CEO of Outline, Jens Sørensen (middle), shakes hands with Area Sales Manager, Allan Them (right) and CSO, Per Jørgensen (left), on the business deal. q
Leading Danish Manufacturer of Windows and Doors Invests in a System TM Line for 3 Reasons Achieving business growth, technological progress, and offering express delivery service were among the reasons why Outline Vinduer decided to place a huge order on a state-of-the-art System TM line – a line that ensures significantly faster production by running almost twice as fast as Outline Vinduer’s previous line.
This System TM solution consists of the following:
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•
An automated feeding system, OptiFeed 6000 Vack
•
A moulder
•
A MiCROTEC Goldeneye 302 scanner with X-Ray
•
An optimizing cross-cut saw, Opti-Kap 5103
•
Company overview With more than 30 years’ experience in manufacturing energy efficient windows and doors, Outline is one of Denmark’s leading manufacturers of wood and wood/aluminum windows and doors for all types of housing. Based in Farsø, Denmark, Outline has 260 employees and is owned by Inwido Group, Europe’s largest window group and listed on the stock exchange.
An automated feeding system, OptiFeed 3000 Vack
•
An automated stacking system, OptiStack 3000 Vack
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A vertical finger-jointer, Opti-Joint V-8
•
An automated stacking system, OptiStack 6000
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Jens Sørensen, CEO of Outline Vinduer:
In the spring of 2018, Outline decided to replace its manufacturing line with a new System TM line to increase its production of finger-jointed laminated wood products. Outline’s previous line had been running for the past 20 years, reaching the end of its lifecycle. ’’The new System TM line gives us a production boost. We have huge growth ambitions. To redeem our ambitions, we must increase our production capacity, and this line helps us get there. One of the unique features of the new line is its special vision system with X-ray technology, which makes it much easier and faster to identify wood defects. The new cross-cut line runs almost twice as fast as the old line, and secures a 5% higher wood utilization’’, says Jens Sørensen, CEO of Outline.
Windows and doors for all types of houses Outline’s products are designed, developed and manufactured in Farsø, Denmark. The company makes customized windows and doors to meet its customer needs and offers the market’s fastest delivery time of only four days.
”The new line gives us a production boost. One of the unique features of the new line is its special vision system with X-ray technology, which makes it much easier and faster to identify wood defects. The new cross-cut line runs almost twice as fast as the old line, and secures a 5% higher wood utilization.’’
The company’s products are sold through timber scanner equipped with visual scanning and Xand building markets across the country to both ray. Besides defect scanning, the scanner can professional and private customers. measure wood density, distance between tree rings and small cracks. Upon scanning, workMeeting a new industrial reality pieces are cross-cut by an optimizing cross-cut Thanks to the line’s high degree of automa- saw, Opti-Kap 5103. tion and intelligence, it simultaneously manufactures two different types of qualities for window After the Opti-Kap 5103, workpieces can either production, both of which are 6-meter finger- be swept straight onto an Opti-Joint V-8 finger jointed workpieces. ‘‘Nowadays, we’re facing a jointer (for A-quality workpieces) or swept onto new reality in which efficient data utilization, a stacking system that stacks them into packs automation and digitization of production pro- (for B-quality workpieces). In other words, the cesses are more important than ever. This grants simultaneous production of two qualities enamanufacturing companies several new opportu- bles excellent utilization of raw material in the nities, but to make full use of them, technolo- sense that Outline can both transport A-qualities gies must be adapted to each company’s needs to the finger jointer and have B-qualities stacked and equipment’’, says Area Sales Manager for and stored in packs. These packs can then be Scandinavia at System TM, Allan Them. ‘‘The reintroduced to the line and finger jointed at a Opti-Kap 5103 cross-cut line is adapted to Out- later time. line’s needs with a focus on product quality, best raw wood utilization and fully automatic hand- Outline to be the focal point at Tech Tour ling. The advanced scanning of wood with color After LIGNA 2019, System TM will be hosting camera, laser and X-ray helps provide maximum an exclusive Tech Tour event in Denmark to give wood utilization and the finest end products. We overseas guests the opportunity to see System look forward to continuing our more than 25- TM’s production facilities and Outline’s line in year cooperation with Outline’’, says Allan. action. Guests will be able to get an up-close experience at Outline’s factory and feast their eyes on a complete range of typical System TM Technical overview Initially, raw material is destacked by an Opti- machinery, as the line is fully integrated with inFeed 6000 Vack feeding system and fed into a telligent scanning, cross-cutting machinery, finmoulder. The moulder follows the curve of the ger-join-ting machinery and advanced material wood, thus reducing the chip removal and en- handling in between all these. The event takes suring better wood utilization. After moulding, place from June 1 – 3, 2019. workpieces are scanned by a MiCROTEC 302
OPTI-STACK 3000 VACK Automated stacking system
OPTI-KAP 5103
Optimizing cross-cut saw
MICROTEC GOLDENEYE 302 SCANNER Detection of defects and quality before cross-cutting
MOULDER
OPTI-FEED 3000 VACK Automated feeding system
OPTI-JOINT V-8
Vertical finger jointing machine
OPTI-STACK 6000 Automated stacking system
Overview: Production:
Windows & Doors
Wood species: Softwood Number of operators: q
Windows by Outline Vinduer
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OPTI-FEED 6000 VACK Automated feeding system
Why Industry Experience Matters: Hassell & Hughes Invests in System TM Turnkey Solution
Hassell & Hughes’ production facilities in Collinwood, Tennessee, USA. q
When it comes to the North American hardwood flooring industry, it is safe to say that System TM is a ‘‘veteran’’ with many years of experience and thorough insight into the needs of hardwood flooring manufacturers. This was the very reason why Hassell & Hughes recently opted for an optimizing Opti-Kap 5103 cross-cut line.
According to Jean-Luc Croteau, Area Sales Manager for North America at System TM, Hassell & Hughes chose System TM due to System TM’s experience, reputation, and ability to deliver on promises.‘‘The residential hardwood flooring industry in the US is like one big family. Everyone knows each other, and word of mouth is extremely important. System TM has many happy customers in this market, so Hassell & Hughes felt it was only natural to choose System TM’’, says Jean-Luc. Hassell & Hughes A company synonymous with quality and efficiency, Hassell & Hughes began as and remains today a family-owned business. The company was founded in 1929 in Collinwood, Tennessee, deep in the heart of forest country. Over the years, Hassell & Hughes has produced various wood products and currently produces quality
OPTI-FEED 6000
Automated feeding system
hardwood flooring as its main product, specializing in Red Oak and White Oak. From manual to automated processes It took a great deal of manpower to operate Hassell & Hughes’ former manual cross-cut line. After facing a labor shortage in finding and retaining skilled labor that could handle physically demanding work, Hassell & Hughes decided to look for a highly-automated cross-cut line and found what it was looking for at System TM. ‘‘This is probably the most advanced line both speed wise and capacity wise in the North American hardwood flooring market’’, says Jean-Luc. Thanks to the optimizing Opti-Kap 5103 line, Hassell & Hughes has replaced more than half of its cross-cut saw operators by automation. In addition, Hassell & Hughes now produces more high-grade products, as the Opti-Kap 5103 line optimizes lumber in terms of lumber grading. Due to the precision of the scanner in this line, Hassell & Hughes can select the best face of its boards. This makes a significant difference for the optimization of lumber in terms of lumber grading. ‘‘This is one of the best aspects of the Opti-Kap 5103 line; being able to maximize overall profitability through use of the scanner’’, says Jerry Hollis, President of Hassell & Hughes. An intelligent line with a special feature In the infeeding process, two unscramblers separate end-to-end boards and place them back side-to-side. These boards are combined
with boards coming in from a rip saw, allowing Hassell & Hughes to control the flow onto the infeed by only feeding what the line needs (a volume control feature). ‘‘If 20% of the boards come from the ripsaw, we can supplement 80% of the line with the end-to-end boards. This way, we always have the right amount of boards entering the next process, the scanner. Basically, if the volume changes from the ripsaw, we’ll supplement accordingly. This is something we developed to make the line more efficient and minimize the need for manpower’’, says Jean-Luc. After scanning by a MiCROTEC Goldeneye 502 scanner, the boards are cut by three optimizing Opti-Kap 5103 saws with double sweepers to achieve increased capacity. ‘‘This is the first line with double sweepers we’ve developed for the hardwood flooring market, which is why the capacity is so high in Hassell & Hughes’ line’’, he adds. During the cross-cutting process, boards are cut into flooring components and eventually profiled with tongue and groove by a moulder. The boards enter the moulder linearly and are set to move at a steady speed, but if an increased number of workpieces are generated by the cross-cut saws, an accumulation system is used to control the flow. When the buffer is full, the cross-cut line can be automatically slowed down. As a result, the flow control system always makes sure the right amount of wood enters the moulder without overloading the operator stationed at the moulder feeder.
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This System TM solution consists of the following: •
An automated feeding system, OptiFeed 6000
•
A MiCROTEC Goldeneye 502 scanner with X-Ray
•
Three optimizing cross-cut saws, Opti-Kap 5103
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Jerry Hollis, President of Hassell & Hughes:
‘‘This is one of the best aspects of the Opti-Kap 5103 line – being able to maximize overall profitability through use of the scanner.’’
OPTI-KAP 5103
Optimizing cross-cut saws
MICROTEC GOLDENEYE 502 SCANNER Detection of defects and quality before cross-cutting
Overview: Production: Flooring Wood species: Hardwood Number of operators: q
To restructure production processes and achieve reliable, high-capacity production, Hassell & Hughes recently invested in an optimizing Opti-Kap 5103 cross-cut line. The Opti-Kap 5103 line maximizes Hassell & Hughes’ overall profitability by optimizing the company’s number of produced high-grade products and by reducing its number of cross-cut saw operators by more than 50%. However, the ability to meet the above-mentioned production needs was not the sole reason that Hassell & Hughes chose System TM. In fact, something else played an even more important role for Hassell & Hughes.
Products by Hassell & Hughes
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Visit us at the following exhibitions: NWFA Expo 2019, Fort Worth, TX, USA
May 1 – 3, 2019
LIGNA 2019, Hannover, Germany
May 27 – 31, 2019
NHLA Convention 2019, New Orleans, LA, USA
October 2 – 4, 2019
Mokkiten 2019, Nagoya, Japan
October 3 – 6, 2019
www.systemtm.com
no. 1 - 2019
System TM, a leading global provider of customized solutions for the solid wood industry System TM offers a wide range of automated material handling systems designed to provide excellent production capacity, maximum wood utilization and reduced labor costs. Our material handling systems are defined as standard system solutions and fully customized solutions designed to meet diverse customer needs.
Opti-Feed
Automated feeding systems
Opti-Kap
Optimizing cross-cut saws
Opti-Stack
Automated stacking systems
Opti-Joint
Automated finger jointing systems
Opti-Solution Customized system solutions
System TM’s prime focus is optimization of staff and wood resources. We streamline production processes and ensure maximum profitability from resource optimization. At System TM, we advise customers by drawing on our technical expertise and knowledge to design the best solution that fits their needs. Please visit our website at www.systemtm.com to find a material handling solution that fits your production requirements.
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System TM A/S
Skovdalsvej 35, DK-8300 Odder, Denmark, Tel:+45 86 54 33 55 Fax: +45 86 54 32 19, tm@systemtm.com, www.systemtm.com