TM News no.2 - 2017 (eng)

NEWS

www.systemtm.com

Designing a cross-cut line to deliver convenience and cost-savings

To help facilitate production processes at Milette Doors, System TM has designed a unique multifunction Opti-Kap 5003 cross-cut line that prepares workpieces for finger-jointing and features a shortcut for workpieces that only require stacking Read the entire article on page 2.

no. 2 - 2017

Maximizing wood utilization and production capacity

with just a little

tweaking System TM surpasses conventional systems in automation and just-in-time production at Aacer Flooring

Read the entire article on page 4 & 5.

System TM has recently assembled a variety of subsystems into an integrated system never seen before in the US. Read the entire article on page 3.

Reaping the profits of manufacturing process changes

System TM has recently replaced Ramsey Timber Group’s former System TM line with a world-class, resource-preserving Opti-Kap 5003 line that makes optimal use of timber quality and consequently, eliminates costs associated with material waste.

Read the entire articles on page 6.

optimization of staff and wood resources

Milette Doors Inc. production facility in Quebec, Canada q

Designing a multifunctional Opti-Kap 5003 cross-cut line to deliver convenience and cost-savings To help facilitate production processes at Milette Doors, System TM has designed a unique multifunction Opti-Kap 5003 cross-cut line that prepares workpieces for finger-jointing and features a shortcut for workpieces that only require stacking.

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Guy Roy, General Manager, Millette Doors: We found the experience to be extremely professional and well planned. The installation of the equipment went well and System TM’s staff is easy to work with. More than that, they are highly qualified and their commitment and dedication in our project was outstanding. We are still in the early stages, but we definitely increased our production capacity significantly.

It was a pleasure dealing with System TM and we look forward to collaborating again in the future.

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Milette’s achievements throughout the years This year, Milette Doors celebrates its 50-year anniversary. In 1967, Gérard Milette founded Milette Doors, a Canadian custom door manufacturing company that produces high-quality doors with sustainable materials and high precision.

Gérard Milette started off by leasing a small plant which was initially run by just his wife and himself. Before long, business took off and the need for workforce expansion arose. As demand grew for his quality products, Gérard Milette boosted his production capacity by establishing his own plants in St-Boniface, Quebec. Although a fire broke out in one of his plants in 1979 and took him back to square one, Gérard Milette brought Milette Doors back on its feet in no time by making slight market strategy changes in 1980. Eventually, this lead to great success and enabled the company to outrun competition. In the years following its comeback, Milette Doors underwent constant expansions to accommodate soaring business volumes.

Today, Milette Doors remains committed to providing high-quality products and services that meet the highest standards within the industry. Milette Doors manufactures

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its products based on strict criteria in terms of style, elegance and performance. In the future, Milette Doors intends to optimize its production methods to increase production capacity, meet customer demand and provide the shortest lead-time within the industry.

An intelligent multipurpose system The Opti-Kap 5003 cross-cut line is a replacement of Milette Doors’ former cross-cut line and its manual crayon marking system.

Not only does this new cross-cut line significantly increase production capacity, but what is truly noteworthy about this multifunction system is its two wood processing options within a single system. Furthermore, it provides exceptional utilization of timber resources and prevents the formation of large volumes of wood offcuts. All in all, Milette Doors has achieved cost savings by purchasing a single system that performs multiple functions rather than purchasing multiple machines. In addition, savings have been made on material costs due to better wood utilization.

The first system option helps process wood in preparation for finger-jointing. This process begins just after Milette Doors’ existing planer, in which a Microtec scanner, Goldeneye 301, scans and defect-analyzes long wood boards. Then, wood is transported to an optimizing cross-cut saw Opti-Kap 5003

saw, in which workpieces are cut in accordance with the specifications of Milette Doors.

Next, an ink printer handles workpieces using distinctive capabilities that have been designed by System TM for the first time. The ink printer marks workpieces with spray patterns based on information provided by System TM’s optimizing software (workpiece type and orientation of items). Ultimately, these spray patterns show the operator/finger-jointing machine how to position blocks post-cutting, as well as the orientation of items when placed in the finger-jointing machine.

Then, workpieces are transported to a sorting line, from which they are distributed into bins or manual stacking stations. To work out space constraints at Milette Doors, System TM has incorporated nine interchangeable bins into the Opti-Kap 5003 system, in which seven of these are generally used. The remaining two function as substitutes, in which one is switched to the other when it’s full. Finally, once distribution is complete, workpieces are transported to a remote finger-jointing system.

The second option offered by this system is intended for products that don’t require grading, as these products only need to be surfaced by the planer and stacked as they are. Thus, this option provides the possibility to bypass the scanner and everything that follows, allowing workpieces to move directly to the manual stacking area.

By Malene Bou Zeid

OPTI-KAP 5003

Optimizing cross-cut saw

•

>>

The optimizing solution from System TM consists of the following:

MICROTEC GOLDENEYE 301 SCANNER Detection of defects and quality for cross-cut

Microtec Goldeneye 301 MultiSensor Quality scanner

•

Optimizing cross-cut saw model Opti-Kap 5003

System TMs optimizing cross-cut line: Production:

Window and doors

Wood species: Softwood Number of operators:

2

System TM surpasses conventional systems in automation and just-in-time production at Aacer Flooring

Aacer Flooring 330,000 sq ft production facility in Peshtigo, Wisconsin q

System TM has recently assembled a variety of subsystems into an integrated system never seen before in the US – a system defined as an automated Opti-Kap 3002 cross-cut line that ensures just-in-time production and gets products out the door faster with an even higher quality than before.

A true northern hardwood flooring manufacturer Aacer Flooring is a leading North American hardwood flooring manufacturer of floor systems for the residential, sports and recreational markets. Headquartered in Peshtigo, Wisconsin, Aacer Flooring uses the finest cutting-edge machinery to deliver products of high consistency, durability and beauty. Aacer Flooring’s products originate from the forests of northern Wisconsin and Michigan, where rich soil and cold weather conditions constitute an ideal environment for hardwoods of exceptional quality, elegance and tight grain.

As a result, Aacer Flooring offers a full line of northern hardwood flooring products in a variety of species, including hard maple, red oak, white oak, cherry, yellow birch, red birch, ash and hickory.

One of the very first fully integrated systems in America In today’s connected world, the ability to integrate systems is becoming increasingly paramount, as the need to link systems together is growing, both within a system under construction and to systems that are al-

ready deployed. Integrating a system is the assembly of component subsystems, often disparate, and making sure these subsystems function as an integrated whole. System TM has recently carried out this task with great success by installing a strikingly unique Opti-Kap 3002 cross-cut line at Aacer Flooring’s 350,000-square feet manufacturing facility for the purpose of producing engineered flooring. The first of its kind in the US, this fully integrated line ties together various supplier subsystems – a roll press, side-matcher, end-matcher, a System TM optimizing Opti-Kap 3002 cross-cut saw, defect removal and a nesting process. The outcome? A highly powerful and harmonized system that surpasses conventional systems which normally consist of several freestanding workstations.

Initially, wood is processed by a heavy duty roll press for the lamination of engineered flooring. The press creates workpieces with hardwood top layers and bottom layers. Using fast curing PUR adhesives, the roll press continuously compresses the top and bottom layers. Once workpieces leave the press, they are placed crosswise and

positioned correctly. Then, the wood passes through a moulder to ensure all planks have the most accurate profiling, tolerances and best quality possible.

Eventually, workpieces exit the moulder with tongue and groove. Next, workpieces are graded, chalk-marked by two operators and placed into a queue that automatically feeds them into the optimizing Opti-Kap 3002 cross-cut saw. A luminescence sensor incorporated into the saw interprets the chalk marks. The positions of the chalk marks are transmitted to the Opti-Kap 3002 cross-cut saw’s optimizing system, which ultimately generates products of the highest value and excludes defects.

optimizing solution from >> The System TM consists of the following: •

Optimizing cross-cut saw model Opti-Kap 3002

Next, waste sorting takes place and a sweeper at the end of the sorting belt sweeps workpieces into a buffer system that automatically arranges and loads them into an end-matcher. The end-matcher shapes the ends for a perfect fit. Finally, workpieces leave the end-matcher and the nesting process takes place, in which workpieces are manually packed according to Aacer Flooring’s specifications.

By Malene Bou Zeid

OPTI-KAP 3002

Optimizing cross-cut saw

System TMs handling line: Production:

Flooring

Wood species: Hardwood Number of operators:

q

Residencal flooring from Aacer Flooring consists of wood from Northern Wisconsin and Michigan.

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The Headquarters in the State of Santa Catarina, southern Brazil q

Frameport’s production shoot manufacturing processes

As part of its plan to decrease manual cross-cutting, Frameport has merged costs, System TM’s four cross-cut lines have been designed to maximize lum

•

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The optimizing solution from System TM consists of the following:

A closer look at the Brazilian timber industry The Brazilian timber industry is a major component of the financial success and stability of the country. Brazil has around 493.5

4 x Microtec Goldeneye 301 Multi-Sensor Quality scanner

•

Focus on optimal manufacturing processes Frameport doors are made of solid pine in a state-of-the-art facility in Caçador, a municipality located in the State of Santa Catarina, southern Brazil. Frameport is renowned for its high-quality and beautifully crafted doors which come in various styles and finishes. Established in 1979, Frameport is currently one of the most innovative and experienced door manufacturers in Latin America.

Attention to detail and high-yield production are just some of the many focus areas for Frameport when turning fresh cut logs into products of unrivaled quality. Thus, applying optimum manufacturing processes serves as a vital factor for Frameport’s development and growth.

8 x Optimizing cross-cut saws

million hectares of forest land, which constitutes approximately 60% of the total land area. Thus, Brazil represents the second largest forested area in the world, only second to Russia.

As an exporter to many countries worldwide, Frameport is well on its way to gaining a strong global position. According to a market report by ITTO (The International Tropical Timber Organization), Brazil’s timber industry is experiencing an increase in export volumes despite uncertainties in the domestic economy.

Decreasing manual defect-marking As part of its ongoing transformation to do away with manual marking of defects, Frameport has extended its former machinery with that of System TM’s and ultimately, altered its production processes. As a result, Frameport will be benefitting from significant

model Opti-Kap 5003

OPTI-KAP 5003

Optimizing cross-cut saws

MICROTEC GOLDENEYE 301 SCANNER Detection of defects and quality for cross-cut

4

labor cost savings, increased production capacity and optimal lumber utilization due to the exceptional speed and efficiency of the optimizing Opti-Kap 5003 cross-cut saws in conjunction with Microtec’s lumber scanning technology.

A custom-built solution on all levels Due to the amount of involvement required to meet customer demands for performance, features and customized capabilities, many providers tend to fall short when customer requirements become complex. This is never the case for System TM. System TM has designed and developed an elaborate solution that consists of four cross-cut lines, each of which consist of a Microtec scanner, model GE301 and two optimizing Opti-Kap 5003 cross-cut saws – in total, four scanners

ts up due to the reshaping of The high-quality and beautifully crafted doors from Frameport: q

d its existing machinery with that of System TM’s. Besides cutting labor mber utilization and to raise production capacities to a great extent. and eight optimizing cross-cut saws. So far, two of the four lines have been installed, while the installation of the remaining two is set to take place soon. With just a little finetuning of the solution and an expanding of line operator experience, maximum production capacity will be achieved in just a matter of time.

Although this solution includes standard main machines, it is highly customized when it comes to the rest of its material handling system; particularly the material handling equipment. This has been custom-designed to process Frameport’s high volumes of workpieces with workpiece conditions that are

intricate to some degree, as they are often curved and small in terms of thickness, width and length.

As for the optimizing Opti-Kap 5003 crosscut saws, these have been custom-made by modifying the standard design of their cross-cutting units. This has proved to be highly valuable to Frameport, as the optimizing Opti-Kap 5003 cross-cut saws can now cut through thin lamellas with perfection and process much larger volumes than the standard Opti-Kap 5003 cross-cut saw.

OPTI-KAP 5003

Optimizing cross-cut saws

To work out space shortages, System TM has configured the solution to fit into the available space at Frameport’s facilities.

This has been achieved by merging together cross-cut systems and by building sorting belt conveyors that run over each other. In conclusion, close collaboration between Frameport and System TM has brought about a solution that will be fully optimizing wood resources, workpiece quality and production capacity.

MICROTEC GOLDENEYE 301 SCANNER Detection of defects and quality for cross-cut

R

MANUFACTURERS OF QUALITY DOORS

System TMs optimizing cross-cut line: Production:

Window & Doors

Wood species: Softwood/Hardwood Number of operators:

5

Production example of a timber component for the UK bedding industry from Ramsey Timber Group q

Reaping the profits of manufacturing process changes System TM has recently replaced Ramsey Timber Group’s former System TM line with a world-class, resource-preserving Opti-Kap 5003 line that makes optimal use of timber quality and consequently, eliminates costs associated with material waste.

From canal boats to timber products In 1890, George Edward Ramsey made a living by building canal boats and barges in Bradford. On September 25, 1979, Peter Ramsey & Sons Timber Ltd. was established.

Now, 127 years and four generations later, Ramsey Timber Group is a leading supplier of timber components for the UK bedding industry.

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John Jones, Operation Director, Ramsey Timber Group: There was no question, System TM again proved to be a perfect partner, as we continued to develop our customer centric 3-year plan, which see’s Ramsey Timber Group improve quality, productivity whilst reducing waste, all culminating to provide unequalled levels of customer service.

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Ramsey Timber Group’s dynamic and innovative vision is based on a commitment to advanced technology, as well as continuous investments in product research and development. On an annual basis, the company sources over 30,000 cubic meters of quality soft and hardwoods. Using high-tech machinery, RTG produces over 1.5 million divan bed bases a year and operates from three sites in Bradford, West Yorkshire – a total of 110,000 square feet of manufacturing and distribution space.

Utilizing wood resources to maximum advantage Ramsey Timber Group has been a valued customer for 17 years that System TM has been happy to equip with advanced production machinery. System TM has recently

made a significant change to RTG’s production process by replacing the company’s previous System TM line with two lines; a moulding automation system and an optimizing Opti-Kap 5003 cross-cut line that includes a Microtec scanner, Goldeneye 301. Essentially, this replacement makes optimal use of all types of wood quality – some of which were previously discarded and ultimately, generating high waste costs.

The moulder line consists of a semiautomatic Opti-Feed 6000 feeding system and Opti-Stack 6000 stacking system. After being processed by the moulder, workpieces are graded and stacked into packs. Upon entering the cross-cut line, the packs are processed by an automated Opti-Feed 6000 Vack. One by one, the processed layers are lifted and placed on a chain conveyor where stability sticks are automatically removed.

Next, the workpieces are transported to a Microtec scanner, Goldeneye 301. Then, scan results are conveyed to the Opti-Kap 5003 cross-cut saw’s optimizing software, which defines workpiece qualities and determines the optimal position for the Opti-Kap 5003 to place its cut. As a result, workpieces are cut

into fixed lengths by the Opti-Kap 5003 saw and stacked by three automatic Opti-Stack 3000 stacking machines.

What is particularly noteworthy about the Opti-Kap 5003 optimizing saw is its remarkable ability to identify and remove defects so as not to influence the quality of the final component. Ultimately, this makes the OptiKap 5003 line highly resource-preserving, exceptionally good at utilizing timber to the fullest and excellent at positioning or removing defects intelligently to keep them from weakening or disfiguring the end-product.

Customer-centric approach As part of their customer-centric strategy, Ramsey Timber Group seeks to achieve improved economies of scale through volume production and customer specific quality criteria, all whilst delivering maximum timber utilization. Due to its increased speed, power and excellent utilization of timber resources, the optimizing Opti-Kap 5003 cross-cut line will be securing Ramsey Timber Group economies of scale for many years to come.

By Malene Bou Zeid

OPTI-FEED 6000 VACK Automated feeding system

MICROTEC GOLDENEYE 301 SCANNER

Detection of defects and quality for cross-cut

OPTI-STACK 3000 Automated stacking system

OPTI-KAP 5003

Optimizing cross-cut saw

•

>>

The two optimizing solutions from System TM consist of the following: Automated vacumm feeding system

OPTI-FEED 6000

Automated feeding system

model Opti-Feed 6000 VACK •

Microtec Goldeneye 301 Multi-Sensor Quality scanner

•

MOULDER

Optimizing cross-cut saw model Opti-Kap 5003

•

3 x automated stacking systems model Opti-Stack 3000

OPTI-STACK 6000 Automated stacking system

Moulder line •

Automated feeding system model

System TM’s optimizing cross-cut line:

Opti-Feed 6000 •

Moulder

•

Automated stacking system model

Production:

Furniture components

Wood species: Softwood Number of operators:

Opti-Stack 6000

6

System TM automates flow production at Roberts Hardwood Flooring by doing what it does best – integrating systems

Robert Hardwood Flooring production facility in Missouri, United States q

To achieve more automation at Roberts Hardwood Flooring, System TM has joined the existing machinery with an optimizing Opti-Kap 5003 cross-cut line. Now, the company enjoys effective utilization of timber resources, increased manufacturing capacity, shorter delivery times and optimized business operations.

A family-owned business of three generations Roberts Hardwood Flooring LLC is a NWFA certified mill that manufactures products of a long heritage of timber workers. Since its establishment in Mountain View, Missouri, in 1981, Roberts Hardwood Flooring has grown from two employees to approximately 100.

Today, three generations of the Roberts’ family are directly involved in day to day operations. Roberts Hardwood Flooring runs its modern logging operations by automating wherever possible, purchasing reliable and powerful equipment, as well as replacing machinery on a regular basis. As a result, Roberts Hardwood Flooring provides its customers the highest quality hardwood flooring available while maintaining competitive pricing.

Let nothing go to waste!

At Roberts Hardwood Flooring, every single scrap of wood is used – literally. After logs are cut and dried, high-grade lumber is either transformed into hardwood flooring or shipped to furniture- and cabinet-makers in the United States and overseas. Wood of

lower quality is converted into landscaping timber and pallets. Indeed, nothing goes to waste at Roberts Hardwood Flooring – even sawdust and woodchips are put on the market for sale.

Increasing productivity through automation Roberts Hardwood Flooring has recently had a new infeed system and ripsaw installed, along with a System TM optimizing OptiKap 5003 cross-cut line. After being ripped by the ripsaw, rips are transported to the System TM and Microtec optimizing crosscut line. System TM’s machinery commences with an incline belt that leads workpieces up to a trimsaw and scanner feeder which feeds workpieces into the Microtec scanner, Goldeneye 302. Upon scanning, the results are communicated to the optimizing software system, which dictates where the optimizing Opti-Kap 5003 cross-cut saw must position its cuts. After cross-cutting, workpieces are prepared by the existing side-matcher, which produces a consistent side matched pattern.

Then, workpieces are processed by the endmatcher, which creates square end joints.

Finally, workpieces enter the nesting and packaging phase, in which hardwood flooring is packed and prepared for transportation.

By coupling Roberts Hardwood Flooring’s existing machinery together with System TM’s machinery, System TM has created a complete and integrated line of high-level automation and efficiency. Since the integration of this line, Roberts Hardwood Flooring has enjoyed significant waste minimization and increased production capacity.

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Gerald Robert, Plant Manager, Roberts Hardwood Flooring We couldn’t be happier with our System TM system.

Great people to work with, great support team, great products, all around great experience!

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A line expansion might lie ahead The design and development phase of the Opti-Kap 5003 cross-cut line has moreover sparked expansion considerations for Roberts Hardwood Flooring in the future.

This might involve adding another cross-cut saw to Robert Hardwood Flooring’s current Opti-Kap 5003 cross-cut line. A potential expansion would require few adjustments to the company’s existing machinery (side-matcher and end-matcher), as well as building in the second saw and corresponding distribution into the current System TM line.

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By Malene Bou Zeid

OPTI-KAP 5003

Optimizing cross-cut saw

MICROTEC GOLDENEYE 302 SCANNER

Detection of defects and quality for cross-cut

>>

The optimizing solution from System TM consists of the following: •

System TM’s optimizing cross-cut line:

Sensor Quality scanner •

Production: Flooring Wood species:

Microtec Goldeneye 302 MultiOptimizing cross-cut saw model Opti-Kap 5003

Hardwood

Number of operators:

7

www.systemtm.com

no. 2 - 2017

Automated material handling systems from System TM System TM offers a wide range of automated handling systems for automation of main machines in a production. Our automated handling machines are designed to dramatically increase the capacity of the main machine and to reduce labor costs.

In order to meet all customer demands, our range of material handling systems consist of both standard system solutions and fully customized project solutions.

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

With System TM’s automated material handling systems, we are able to advise and supply you with the right solution to fulfill your specific requirements and demands, and to obtain a more efficient and profitable production.

Please visit our website at www.systemtm.com and find the material handling solution suited for you and your production.

A look back on LIGNA 2017 LIGNA has yet again demonstrated fantastic results in terms of innovations, worldwide appeal and a significant increase in number of exhibitors and visitors from all around the world.

This year, LIGNA attracted more than 1,500 exhibitors, including 900 from abroad.

A total of 93,000 visitors from more than 100 different countries came to see the world’s leading industrial trade fair for machinery, plant and tools for the woodworking and timber processing industry.

Allied powers History has repeatedly proved that it’s always easier to stand up against an opponent with the strong support of allies that put their resources together. In a business

sense, pooling resources provides access to the unique know-how of the partner companies. At LIGNA 2017, System TM situated its largest stand so far beside its valued partner MiCROTEC and collaborators. Gathering in one location in hall 27 made it easier for us to draw on the expertise of each other when the need for supplier machinery arose during customer project discussions. Thus, we formed one powerful unit by putting all our strengths together.

Raising the standards for cross-cutting This year, System TM’s star of the show was its brand-new cross-cut series, the OptiKap 5100, which was well-acknowledged and notably appealing to its audience at LIGNA 2017. Opti-Kap 5100 was proudly revealed at LIGNA 2017 as a subsequent development

System TM A/S

of the Opti-Kap 5000 series. It is safe to say that this remarkable saw has raised the bar for cross-cutting due to its phenomenal features – improved user-friendly operation, stronger construction and more intelligent control software, all of which ensure maximum uptime.

Building strong brand equity At System TM, we enjoy showcasing the full spectrum of our equipment in action. Our frequent daily demos of running machinery attracted many curious crowds to our stand at LIGNA. What also captured the attention of our guests was the design and layout of our stand. According to many first-time visitors, qualities such as proficiency and competence were associated with the overall physical appearance of our stand. This made

visitors feel a sense of security toward our brand and ultimately, helped grow brand equity.

Counting down to LIGNA 2019 After five busy, yet fulfilling days, System TM can look back on an extraordinary LIGNA show that has generated many viable sales leads and potential business collaborations.

Thus, LIGNA continues to prove its value, as it once again presents abundant opportunities for business promotion and brand awareness strengthening.

On that note, we truly look forward to another exciting LIGNA show in 2019!

Skovdalsvej 35, DK-8300 Odder, Denmark, Tel:+45 86 54 33 55 Fax: +45 86 54 32 19, tm@systemtm.com, www.systemtm.com

By Malene Bou Zeid