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Plant D manufacturing processes consist of graders and stacking, air drying, kiln drying, rip saws, chop saw, moulder, end matchers, grading and nesting/bundling. Lumber comes from the suppliers, and is graded and stacked to be air dried. When the lumber reaches 20% moisture content, it goes through the kiln drying process to be dried to 7-8% moisture content during 12 days. After the lumber is dried, it goes through the rip saw machine, and then to the chop saw where any large defects presented in the boards are removed, so the quality can be improved. After the chop saw, the boards are sent to moulder, where the pieces are moulded into flooring and stamped with the company logo. Then, the flooring goes through the end matchers to be squared and acquire a UV sealer. After the end matchers, the floor boards go through another grading process and then to the nesting machine where they are bundled and ready for shipment. In the case of air drying and kiln drying, processing times were 42 and 12 days respectively. Processing times are higher than takt time which makes these two processes bottlenecks of the operation. The company needs to have dried lumber for 42 days so they can supply the flooring production line which leads to higher inventories in the air and kiln drying processes. The takt time obtained for plant D was 588 sec/MBF. Cycle times obtained for the rip saw, chop saw, flooring, end matchers, grading and nestling/bundling were 360, 377, 452, 452, 516 and 516 sec/MBF respectively. The obtained cycle times are lower than takt time so the company does not over or under produce; and to ensure that the customer’s demand can be met. The rip saw cycle time indicates that the machine produces faster than demand, which led to inventory between the rip saw and chop saw. The same situation can be seen for the chop saw. The average yield of the rip saw, chop saw, moulders, and end matchers are on average 87%, 83%, 98%, and 88% respectively. The time line shown in figure 9 represents the lead times of the non-value added times(WIP) that are presented in the manufacturing process of flooring at Plant D. The inventory was calculated as a lead time by dividing the inventory levels by the daily demand. Value added times were considered to be the processing time of the machines. The total production lead times was determined by summing up the upper and bottom values of the timeline. 103PDF Image | Impact of Vacuum-Drying on Efficiency of Hardwood Products
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