On the Move
Five-year capital investment plan positions Iowa sawmill for future markets.

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Moving upstream, the 2002 project replaced a circle saw headrig and debarker. The company purchased a late model used Morbark rosserhead debarker and modified the tooth design to prevent fiber damage. An MDI metal detector is installed after the debarker. Logs advance to a McDonough three-knee 17 degree tilt carriage and McDonough 7 ft. bandmill headrig.

Primary breakdown is optimized with Inovec StereoScan laser scanners and YieldMaster controls software. This was the mill's first experience with optimized systems and it created not even a hiccup in startup. The Kendricks have been well pleased with yield improvements it has provided.

The company's close scrutiny of forestland management and timber harvesting help maximize log quality and inventory.

Logs may be two-sided, squared or processed for grade at the headrig, depending on the species and production flow. Cants then proceed to the McDonough linebar. Sideboards transfer to a Timber Machine Technologies (TMT) two-saw board edger, which was installed in 2003. It is also equipped with Inovec's StereoScan lasers and WaneMaster optimization software.

Based on customer preferences, the mill does not end trim its production, but that capability would be added as customer demand changes. Lumber goes to a two-man inspection chain, where one concentrates on grading only and the second keeps up with the tallies. Rhonda reports they are considering buying a tally or grade system to directly input this data into the computer information systems.

TMT two-saw edger was added in 2003 with Inovec optimization.

Pilers sort lumber into 11 separations, excluding cants and railroad ties. An in-house built stacker prepares lumber packs for drying. Two Sellick SB60 forklifts feed kilns, air-dry yards and load contract haul trucks for delivery to customers. Walnut lumber goes to an in-house built steam bath, which injects live steam to evenly distribute the characteristic dark coloring throughout the board.

With these installations in place, throughput capacity was more than was really needed. "The mill was so fast, we were probably on the road to producing 12 million board feet," Rhonda states. "It sounds wonderful to jump like that, but it causes problems in your logging, your trucking and things like that. So we brought it back down." Annual targeted lumber volume is 9.5 to 10MMBF. "We can increase annual production in smaller increments, so it doesn't impact our operation downstream," she adds. "Our six year goal is 13MMBF."

Inovec optimizers have provided measured yield improvements of up to 17% in the preferred oak, walnut and cherry species. Company personnel continue to fine-tune their yields and production performance. This year capital investments were focused on the physical facilities. A new maintenance shop and office complex were built in preparation for future growth.

As for maintaining cutting tools, saw filer Bill Meyers uses Armstrong and Hanchett grinders, and a Hanchett leveling bench to maintain the band saws. Kerf is .145-.147. Simonds band saws are purchased direct from McDonough Manufacturing. Carbide tipped 24 in. edger saws go to Wilson's Woodshop & Sharpening Service in Manchester, Ia.

ALWAYS LEARNING

Kendrick Forest Products employs 54 and boasts of a high employee retention rate. Average tenure is 7 years, 4 months, according to Sawmill Manager Kevin Funk.

The operation entered the cabinet business in 2000.

Earlier this year, the company paid for all employees to attend a two-day training course on "lean manufacturing" philosophies at Northwest Iowa Community College in Dubuque, Ia. Key employees stayed on for a more in-depth study that lasted through the week.

"We've changed our way of thinking a little bit," says Rhonda, who looks after the production side, while Tim handles the forestry and logging division. "Lean manufacturing teaches you to reduce your inventory and to work in smaller batches."

As a result of this training, previous plans to expand kiln capacity are now being reconsidered. Instead, Rhonda explains, they may decide to split an existing 50,000 bd. ft. kiln into two cells, reducing the volume of a specific product or species that must be staged for each charge. This modification would give them more flexibility with smaller orders while still operating kilns efficiently and keeping the lid on inventory in the warehouse.

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