Lowe, George

Western Dry Kiln Association

Western Dry Kiln Association. Meeting (55th : 2005 : Reno, Nev.)

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CASE STUDIES IN LUMBER DRYINGTHE MEASURABLE IMPACT ON PRODUCTIVITYGeorge LoweMatrix NorthwestSeattle, WashingtonINTRODUCTIONI'm George Lowe, President of Matrix Northwest. The mission of Matrix is to increaseprofitability for our customers by introducing them to energy conservation products andservices. Matrix has been marketing the Enercon orifice condensate removal unitprimarily in the Northwest, California, Idaho, Montana and Wyoming.BUSINESS CASE STUDIES PROGRAMWhen Matrix began to convert plants to orifice systems, we knew that we were going toproduce savings for the plant – less fuel use, elimination of maintenance costs, areduction in make-up water, and a reduction in chemical costs for treating water throughthe boiler.In 2003, Hampton Lumber converted all of its 6 Washington plants to Enercon's orificesystem despite hearing that orifices wouldn't work with varying loads. C&D Lumberconverted its plant in Oregon. Hampton reported reductions in drying time andimprovements in drying consistency, as well as savings in fuel, water, chemicals andmaintenance. C&D Lumber reported improvements in drying consistency along with fueland maintenance savings. Following these successful conversions, 47 plants in the U.S.installed orifices on one or more kilns in 2004.As more plants installed orifices in kilns, we began to get more reports and anecdotalevidence that orifices impacted variables .of production and quality, but we couldn'tquantify them precisely. One business owner challenged us to produce a good businesscase for converting all of his plants to orifice units. The Business Case Study Programwas launched. We wanted to find out, what is the relationship between the savingselement and the production impact? If a conversion impacted productivity (measurable),what is the resulting impact on a company's profitability?Could we use reduction in charge time as a proxy for increased production capacity? (Wedid for the purpose of this presentation). Could we establish a unique causal relationshipbetween converting all of the kilns and an increase in production? We kept hearing frompeople in the industry, that "consistency" was important and was improved, that "capacity"was increased and that "Uptime" was increased. But how do we measure what impactthese three variables have on increased productivity?One thing we realized is that we had to begin to systematically start collecting data onproduction and quality and try and answer some of these questions. We have includeda copy of our one page questionnaire in Appendix 1.Since we are embarking on what amounts to a full-scale economic analysis of each plant,let's look at the basis economic theory. Every company has a production curve which isWestern Dry Kiln Association76	 May, 2005impact of orifices on produc iv(shifts curve to left).•0#a bundle of inputs — labor, staff, raw materials, production structures (kilns), steamdistribution system, etc. How these are all managed together is the company's productioncurve profile and each company's will be different and unique.The results of data corning in to date indicate that the process of converting is an externalevent outside of the normal bundle of inputs to the production curve and actually has theeffect of shifting the entire production curve. This is demonstrated in Graph 1.Graph 1Business Production CurveCompany A	Company BBundle of InputsSo we began the collection and analysis process and we found what everyone in thisroom already knows, that everyone is extremely busy and doesn't have a lot of time to gointo old reports and dig up baseline data. So our data set was incomplete with lots of gapsand we couldn't do very much in the way of company comparisons. Here's what we'vegot.The data presented in this paper is the result of collecting data in the Timber Industry fromsawmills. By April 31, 2005, Matrix had the following results:25 Complete Plant Conversions12 Partial Plant ConversionsWestern Dry Kiln Association	 77	 May, 2005Reported Charge Times Fran 15Companies h 2004 and 20050	 2	 a	 6 6 10 4 1a 16Compani.camen0Val aim-osaw.CI)2 03%6°e 621%ra_.....01:17*For this initial and preliminary study we have compiled data from 15 plants.We have two graphs to show you.Graph 2 outlines the fifteen plants and an outline of the various production factors that gointo the drying process. Many of these factors we have identified as perhaps being partof what influences the productive capacity in the kiln drying process. We were looking fora pattern that would help us make apples to apples comparison and allow us to see theimpact of converting to orifices. So far we think our sample is too small but as we get moreand more data in we can build up the matrix and see if any patterns emerge.Graph 2Factors In The Drying Process•2•F10311:221111111111111" .9- 4' 4' vgIIIIEIIIREIIEIMICIEMEIMIIUIEIEICUIEIMIIEIEIIUIIIICIIINM	 300%1111:11111:111111111111M111110111111111:111111101101111NEM 3 50% C1111111111111111171111311101111CIEUME11111-P	 " ..,'•" in'	 Cr	.. qs 4 e 4.70NEEME1113•MN 4 00% 111•011113110••111111111111111111111rinosiummunimmaumNM 00 CIIIIMIIIIMIEIEIMMIC1111111111111111111111WEI 000%0EIMICIIIIIMMIIIIIIMMIDE31111MN 1 0014101351111111111E111111MMIIIMMIIIIMMIMil 3 IMIN•IIIII••CIIIIIIIRMIIII••ingi 13 40% EILMICIMICIIIIMMIEIMICIIIIIIIIIMEMEEEMEICISIIIIIIIImmouommumm••Ism 1 5.00% 111111100EI0•MI0CEI•I••MN 0 101111111M111•11111101111110111111111111111111111111CIMIC11011111•1111013111WHIIMENI--MEM 24 00%11.11111.1.111111111111EMEHOMMOMNIMI(c) 2005 MatrixLooking at Graph 3, we simply plotted the range of percentage charge reductions and wenoticed a very distinctive overall trend in charge time reduction. Certainly there was a widerange from 2.5% to 24.4%.Graph 3Western Dry Kiln Association	 78	May, 2005LowerChaqe hrslOtowerDael0 Upper Charge hrstO*UpperDatel01)Wen =CV	 '46 Man =Q704-9.T."—".---"---"sLowerChagehrst2*iowerDael2a09Mllean:2.67	 Y6 Nean.9933a1--;----'--.-----'-`---.■y21)9Ineen =AR	 TS 4..62.33UpperC ha qe hrs12*UpperDatel2 586Charqe hrs10*%6Datel0 586C haqe hrs12"5E0atel2144.1,1=45.67	 %Mem = ,620 4 ,„ +0r------.."--------,4„...*Atm= 6L00	 Mlle. .592It1)4Mean =GOB 	 t6 P441=61.00chaqehrs*datefor a Plant in OregonDrying times for 2 x 10's & 2 x 12's vs, kilnsPre orifice vs. post•orificeOvi:fill drying time ingronwit = 325%itScatterplot---Th448When we looked at, from one particular company that gave us more complete data, someof the three month baseline data (before installation) from 2004 with the same period oftime post-installation the trend was generally down but in a few cases in some kilns it wentup and tended to reduce the system average when we ran it through our statisticalsoftware package.We began to compare charge times with particular kilns and with different timber sizes.If we look at this from the perspective of production control, this is where the big story is.There is less variation in the process and the output data is grouped much tighter. Wecan see this in Graph 4, which shows a scatterplot for a variety of kilns and timber froma sawmill in Northwest.Graph 4This graph represents a comparison of charge times by lumber widths between kilns. Themean-reductions are shown on the graphs. Notice the actual increase in Kiln 5/6.Apparently, there is still some variation that we did not account for and, thus could notisolate. The chances are, this isolated variation is having an effect on 2x12's run in thatkiln, as well. The last "All Widths" graph shows individual data points plotted for a totalcumulative mean reduction of 3.85% for all widths and kilns for 2005.We get an even better look at the issue of variation and grouping in the three boxplotsfrom the same company in the Northwest as shown in Graphs 5a through 5c.Western Dry Kiln Association	 79	 May, 2005Newry - MwthVaVirda whitsSoviet of Middle Kiln (mean hours)Upper Kiln boxplot shows both a mean reduction (with a 3.56% drying time improvement)and a process variation improvement with an Interquartile range (IQR) reduction from 8to 5. This says that kiln charge times are and will be more predictable than in the past.The same holds true for the lower kiln. IQR goes from 5.5 to 4.0. The boxes representthe interquartile range. The vertical line is the total range with the means connected.Drying times are reduced 6.23% for the lower kiln in January-March 2005 over January–March 2004. The summary of this is: not only do we see lower drying times in thecomparison periods, but the up and down of charge time variation is less, too.Graphs 5A, 5B, 5CWestern Dry Kiln Association	 80	 May, 2005The Middle kiln plot shows that the mean drying time improvement trend continues. Thegains on process variation, seen with the other kilns, aren't as great here, as shown withan interquartile drop of 10 to 9.5. This is probably due to the as yet, undiscoveredvariation. However, the mean drying time reduction is still a robust 5.47%.WHY WOOD DRIES FASTERFaster drying with orifices is mostly due to improved heat transfer in the coils. Mechanicaltraps produce inconsistent temperatures, where heat transfer capability at the bottom ofthe coil is lower than the heat transfer capability at the top of the coil. With orifices, thereare more btu's per pound in the coil throughout the coil. To a lesser extent, faster dryingtimes are due to wood drying evenly, so you're not waiting for wood at the bottom of thecoil to dry when the wood at the top of the coil is already dry.OTHER VARIABLES REGARDING PRODUCTIVITYOther variables that impact productivity are:(A) More uptime — this is an important factor to many plants to keep up productivity(B) More supply capability — plants have reported additional supply capability whichtranslates to more consistent steam flow. Some plants have reported the capacity to runan additional kiln.(C) Improved drying consistency and grade recovery — we have anecdotal reports ofimproved grade recovery. The kinds of things we hear about improved drying consistencyare:"The top layers of lumber are drying flat instead of twisted.""Before, one side of the kiln came up slower, now both sides dry the same.""My wood is drying a little more evenly."In some cases, improved drying consistency could lead to better grade recovery and thisis something we are starting to investigate.For some plants that use natural gas or other fossil fuels, saving on fuel costs per boardfoot is still the most important factor. The average reported fuel savings among kilnoperations has been about 12%, which is similar to other industries. Orifices are betterthan steam traps at 1) holding back steam and 2) letting out the water. If the mechanicaltrap is closed, it is not letting the water out. If it is open, it is letting out enough steam tocause a pressure gauge to drop. With an orifice neither of those will happen so an orificedoes a better job on both sides of the trap.Many people at the plants we work with say it makes a big difference to them that they nolonger have to constantly check to see if steam traps are working properly and no longerhave to repair or replace them. The Enercon orifices start out more efficient than newmechanical steam traps and retain their initial efficiency indefinitely. (They have a lifetimewarranty). This means kiln and maintenance personnel can spend their time on otherissues.Western Dry Kiln Association	 81	 May, 2005CONCLUSIONSProductivity ResultsAs we collect more data we'll be able to see more clearly what the improvement in dryingtimes is for kilns, and why the drying time reduction is greater in some plants than others.The data collection process has been messy and varied. Nevertheless, the data doesreveal an across the board average increase in potential output caused by reducedcharge times.In Appendices 2 and 3, we have included drying time reductions reported to us by StimsonLumber in Gaston, Oregon and Hampton Lumber's Cowlitz division. Their results aresignificant and they have given us permission to share their results with you. Hampton'sCowlitz division has had the benefit of being able to look at drying times over a year.For many customers, the improvements in drying time and drying consistency have greatlyoutweighed the benefit of orifices saving money in terms of fuel efficiency andmaintenance elimination. Many plants have already reported having several paybacksin a year from reduced drying times, additional supply capability or fuel savings, or acombination of benefits.Quality Improvement ResultsRegarding the increase in quality due to increased grade recovery percentages, the littleevidence we have so far is mixed. High increases in grade recovery were reported bythree companies (1.5% -6%) while others (three companies) reported closer to an averageof no change in the grades recorded. Our preliminary conclusions are that the impact sofar in grade recovery ranges from neutral to positive. As more data comes in we will refinethe results.Western Dry Kiln Association	 82	 May, 2005APPENDIX 1Matrix Northwest, Ina - Business Case Study WorksheetYour PlantBaseline Data and Assumptions Used in Business Case StudMay 4, 2005 Be oreConversionAfterConversionHaire of your companyDid you have a steam trap maintenance program beforeHow many s•oarn traps did you have? Then/NHow often Is a complete thedc of all traps done? (monthWhen was the lost time you repaired all the Warn traps? (monthHow many boilers do you have?at pressure did you my too your pipes? (average if several) Then/NWhat type fuel do yeti uWhet is your oust per 1,000 Its of steam?How many days a moat/ do ye.; run your steam syslf you use injected steam, what pcncent is infectWhat is your start up lane?Is water usage Critical to VOW company?What is yrair cost of water(indude dimensions Of attributes - cubic feet, gallons per minute, etc.Yesurnmonthsmonthsboilerspsi°GasOilt	 ocr(gas)dayses/nota$0.00199 iseattle's rate)111111111111111111111111111111111111111111111Nov., muchfeed water makeup did you add to wtu system daily.Monthly bill for Chemicals for your steam systemDaily Rate of Maintenance StaWhat is your rated boiler output?What is your average annual profit margin'.Is there anything special I need to kno4, about your steam system'TDrums your company have cogen or are you mnsiderine it?Is a reduction in ernissns important to your cornpayrDo you rave remote sensing capabilites to monitor your systemTimber Industry OnlyWhat percent of your wood do you dryWhat percentage of your wood produced is green.What species do you dry'Describe your productAnnual Throughput through: kilns .n f10 Ft per YeaWhat percentage of your kiln dried product :$ GradeWhat percen tage of your kiln dried product ,s GradeWhat percentage of your kiln dried product is Grade 3Whet percentage of your kiln dried produc t. is GradeWhat average price do you earn from Grade'What overage price do you earn horn Grade 2What overage price do you earn front Grade 3What average price do you earn horn Grade 4How many kilns do you apeHow many kilns do you net tyrough van,ratIng your olanor at reduced production leo eto accommodate kiln drying limitAon,Are the wile gangedIf ganged, how many coils totevadabie based on moisture coctenyour typical cycle time on your kilns'CO GEN ONLYHow much Power do you current, CoGen?iWhat are your turbines Peak capability?;	What perwrge of your steam goes to CoGen?1		How much income do you generate with CoGert? Monthly)/ 	'00 0Do you run a set scheduleWhatgale shared make-upshared again• our ratehp -=:?:r-FI:4'-:r- Blade	 el<- use vex estimatee.g. 30 day codeyes 1 no / already haveyes: ronor nunany do s in winter+down the opereti g kiln counto reflect thatyes,' roeyore best esrYWdte n	 rlabCopyright lot 2005 Matrix Northwest, in-Western Dry Kiln Association	 83	 May, 2005Appendix 2Stimson Lumber — Gaston, OregonDrying Times Before and After Orifice InstallationTYPEFIRKILN HOURSBEFOREHOURSAFTERIMPROVEMENT2x4Fir 2 32 292x6Fir 2 34 282x8Fir 2 31 27Averaggs 32 28 13.40%HEMLOCK2x4Hem studs 4 61 502x4Hem studs 4 62 502x4Hem studs 4 57 51Averam 69 50.33Appendix 3Hampton Lumber — Cowlitz DivisionKiln Performance GainsKiln time improvementsMorton: 13%Randle: 13%Packwood: 18%HDC: 15%Division: 15%10 hour improvement average division wide(measured over approximately one year)Western Dry Kiln Association	 84	 May, 2005

Case studies in lumber drying the measurable impact on productivity

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Case studies in lumber drying the measurable impact on productivity

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