Statistical Considerations for Real-Time Size Control Systems in Wood Products Manufacturing

Currently, sawmill machinery companies are developing real-time size lumber size control systems using non-contact laser measuring systems. These systems rely on the application of industrial statistics to large quantities of lumber thickness and width data. Because of the sampling intensity and frequent decision making in real-time systems, there is an increased chance of committing Type I or Type II errors when drawing conclusions if statistical methods are incorrectly applied. There is confusion in the industry concerning the appropriate statistical model to use for lumber size control. This survey of the current literature discusses three distinct methods for calculating and partitioning sawing variation, and thereby calculating control limits for control charts. This paper reviews the statistical foundation and current understanding of industrial statistics for implementing real-time SPC systems and makes recommendations for improvement

Reliability Testing of Statistical Process Control Procedures for Manufacturing with Multiple Sources of Variation

Quality inconsistencies can be caused by processes with multiple sources of variation. Therefore, the development of control charts that perform properly for both producer's and consumer's risk can be very complex. This is particularly true for real-time SPC systems that collect a great deal of data through noncontact sensing. In this paper, we demonstrate the use of a Monte Carlo simulation procedure that can be used to test SPC charts for both consumer's and producer's risk, and an experimental design procedure to analyze the results. This procedure is shown to be especially useful where design factors interact to cause high variation in a quality characteristic of a product. The approach is illustrated for a practical problem taken from the lumber manufacturing industry and demonstrates that commonly used industrial practices to control product dimensions lead to erroneous conclusions. To that end, a new mathematical approach that yields the correct results is described. The Simulation / ANOVA procedure described in this paper may have applicability in the control of many other industrial processes

SPC Methods for Detecting Simple Sawing Defects Using Real-Time Laser Range Sensor Data

Effective statistical process control (SPC) procedures can greatly enhance product value and yield in the lumber industry, ensuring accuracy and minimum waste. To this end, many mills are implementing automated real-time SPC with non-contact laser range sensors (LRS). These systems have, thus far, had only limited success because of frequent false alarms and have led to tolerances being set excessively wide and real problems being missed. Current SPC algorithms are based on manual sampling methods and, consequently, are not appropriate for the volume of data generated by real-time systems. The objective of this research was to establish a system for real-time LRS size control data for automated lumber manufacturing. An SPC system was developed that incorporated multi-sensor data, and new SPC charts were developed that went beyond traditional size control methods, simultaneously monitoring multiple surfaces and specifically targeting common sawing defects. In this paper, eleven candidate control charts were evaluated. Traditional X-bar and range charts are suggested, which were explicitly developed to take into account the components of variance in the model. Applying these methods will lead to process improvements for sawmills using automated quality control systems, so that machines producing defective material can be identified and prompt repairs made

Testing a silvicultural recommendation: Brazil nut responses 10 years after liana cutting.

1. Lianas or woody vines can be detrimental to the trees that support them. Research on liana cutting for tropical timber management has demonstrated positive yet costly benefits, but liana utting to enhance commercial outputs of nontimber forest products has not been examined. We implemented a controlled experiment to quantify the effects of cutting lianas on Brazil nut Bertholletia excelsa Bonpl. fecundity. 2. We conducted our 10-year experiment in a Brazilian extractive reserve where local harvesters collect fruits from this Amazonian canopy-emergent species as part of their forest-based livelihood system. We cut 454 lianas with a total basal area of 2 41 m 2 from 78 of 138 host trees ≥ 50 cm diameter at breast height. 3. Treated trees were significantly better producers 3 ½ years after liana cutting, and these differences increased dramatically in subsequent years, with consistent proportionally higher production in treated versus untreated individuals. 4. The number of lianas rooted within 5 m of the host tree significantly explained production levels, suggesting both above- and below-ground liana ? host tree competition. Once host crowns were liana-free, branch regrowth was highly visible, particularly in heavily infested trees, and crown reassessments suggested that liana cutting improved crown form. Additionally, liana cutting may induce some nonproducing trees to become producers and may circumvent mortality of trees heavily infested with lianas (> 75% crown covered). 5. Liana removal can be implemented easily when harvesting Brazil nut fruits. Only lianas associated with B. excelsa trees should be cut to conserve liana ecosystem functions. 6. Synthesis and applications. We quantified effects of liana cutting on Brazil nut host tree fecundity and provided estimates of increased commercial yields. Our long-term (10-year) study permits understanding of biological variation and informs related management decisions. Findings suggest that liana cutting reduces above- and below-ground competition with individual trees, ultimately allowing mature host crowns to recover such that 9 - 10 years after liana cutting, treated trees produced on average three times more fruits than untreated trees. Application of liana cutting to other tropical species would likely boost fruit and seed production, increase host tree fecundity and potentially enhance future recruitment

The evolving role of Bertholletia excelsa in Amazonia: contributing to local livelihoods and forest conservation.

O papel em evolução de Bertholletia excelsa na Amazônia: contribuição a modos de vida locais e conservação florestal: In the last three decades, Brazil nut (Bertholletia excelsa) has emerged as a cornerstone species for Amazonia. This has gone hand-in-hand with the creation of extractive reserves, an alternative land use model to balance biodiversity conservation with rural development, whereby traditional forest residents are assigned legal responsibility for co-management of these reserves and their resources, including Brazil nut. The essential role of this species in conservation and local livelihoods has precipitated a shift from general exploitation to more conscious, intensive management

Sustainable forest use in Brazilian extractive reserves: natural regeneration of Brazil nut in exploited populations.

The emergence of Brazilian extractive reserves reinforced the notion that sustainable forest use could play a central role in conservation. Brazil nut is considered a model non-timber product for promoting conservation through use. Demographic studies, however, have demonstrated differential impacts of nut harvest on Brazil nut population structure. Comparing three populations with different forest use histories, degrees of road access, and recent levels of nut harvest, we asked: (1) Are they exhibiting regeneration failure? and (2) Are seedling/sapling densities explained by adult Brazil nut structure, fruit fate and/or overall forest structure? We installed four 9-ha plots in each site to census Brazil nut trees > 10 cm dbh, and within each plot, 36 subplots (25 × 25 m each) to quantify regeneration, overall forest structure, and open and closed fruit counts. Approximately 29-55% of fruits was unharvested, and more than 90% of these was opened by scatterhoarding dispersers. Population structure approximated a reverse-J size class distribution, with seedling densities varying from 3.2 to 5.8 individuals ha-1. We conclude that within the current harvest context, regeneration is sufficient for population persistence in our sites, at least over the medium term. The socioeconomics of sustainably managing Brazil nut is the greater challenge, involving interlinked competitive land uses, nut quality, and substantial increases in local income from harvest. Some of these challenges are being addressed in Brazil, Bolivia and Peru, providing hope that this cornerstone extractive species will continue to play a prominent role in the ecological and economic landscape of Amazonia

Swidden fallow management to increase landscape-level Brazil nut productivity.

Brazil nut (Bertholletia excelsa Bonpl.) is considered the cornerstone non-timber species of Amazonian conservation. Nuts (or seeds) of this massive tree are harvested by local people living in and near old growth forests, supporting local livelihoods and regional economies. Secondary forests, however, particularly plots previously used for agriculture (swidden fallows), present better B. excelsa seedling and sapling recruitment than mature forest. This study examines the extent to which forest residents could increase nut productivity by allowing their fallows to grow into Brazil nut rich forests. We conducted B. excelsa inventories in the Brazilian state of Acre in abandoned swidden fallows of different ages. We also conducted interviews to determine landowner perspectives on the fallow potential for increasing nut production. An individual-based model, based on in-situ inventories and primary and secondary datasets from prior fieldwork, simulated growth, survivorship and production from the 250 inventoried trees in 18 fallows of varying sizes (from 0.41 to 4.18 ha) and different regrowth stages (12 to 60 years old). These simulation model predictions showed that after 10 years, 2.4% of existing trees would be productive, with an average of 68.6 ± 21.5 fruits per reproductively mature tree in the four fallows that most quickly yielded productive trees. By the final projected time interval (40 years), predictions suggest all fallows will produce fruits with cumulative production averaging 1475 ± 359 fruits ha?1, suggesting an increase in landowner income of US$55.1 ± 13.4 per hectare of fallow. Our simulation model is the first to explore fruit productivity of Brazil nut in secondary forest. It likely underpredicts B. excelsa growth and nut production, considering that swidden fallows provide better resource availability than the forest-derived datasets we used to construct the model equations. In conclusion, our findings support previous research that suggests that higher B. excelsa recruitment rates observed in abandoned swidden fallows could indeed translate into greater adult densities and thus potentially, higher nut production – a conclusion mirrored by most participant landowners

Are Brazil nut populations threatened by fruit harvest?

Harvest of Brazil nuts from the large, iconic tree Bertholletia excelsa generates substantial income for smallholders, providing a strong incentive to conserve the mature forests where it grows. Although much previous work has focused on the impact of nut harvest on new seedling recruits into B. excelsa populations, the connection between harvest rates and long-term population stability is still unclear. Moreover, there is additional uncertainty for Brazil nut management in terms of population response to climate change and other anthropogenic influences. We drew on 14 years of research in two sites in Acre, Brazil with different B. excelsa nut harvest intensities (39% and 81%), to produce stochastic and deterministic matrix population models which incorporated parameter uncertainty in vital rates. Adult abundance was projected to remain close to the current observed abundance or higher through the next 50 years. Elasticity analyses revealed that the asymptotic population growth rate (λ) was most sensitive to stasis vital rates in sapling, juvenile, and adult stages. Deterministic transition matrices calculated using diameter growth rates dependent on rainfall yielded average λ values around 1.0 under extreme high, extreme low, and average annual rainfall. While sustained high rates of Brazil nut harvest and climate change could potentially negatively impact B. excelsa populations, changes in human use of the forested landscape are more immediate concern. To reduce the risk of population decline, smallholders and managers of B. excelsa rich forests should focus on conservation of pre-mature and mature individuals