Automated Wrappers:
It would be great to have a cost effective automated wrapper
for lumber and wood products with a zero defect tolerance. While there have
been a limited number of companies who have put in automated systems for
packaging bulk items, the truth of the matter is, that automated wrappers have
historically only been a mess for companies in the wood product industries. The
issue comes down to limits in plastics, limits in sizing, but more importantly
the ability to provide a cost effective packaging requirement with limited
defects. Changing out roll-stock on an automated line and consistency in
packaging quality has not surpassed the ability for Joe Blow on the packaging
line to effectively apply wrap or a cover. But the most important issue with automated
wrapping machinery deals with the outcome of a down automated wrapping machine.
This brief post will examine the effectiveness of an automated wrapper vs. the
end-line packaging team or individual who has been wrapping lumber by hand.
It would be great to
have a cost effective automated wrapper for lumber and wood products with a
zero defect tolerance...
but is that possible?
A few years ago there was a mill in the Pacific Northwest
that had put in an automated packaging machine on their sawmilling line. The
results: an expensive piece of machinery, with a specific dedicated plastic
requirement, with a reduction of one employee, though inconsistency in quality
packaging (this mill has since taken out the machine). To further detail these
areas, a cost-benefit- analysis needs to be completed on the value of a piece
of machinery that automates the wrapping.
A new machine in the packaging line still requires an
individual to run the machine, or at the very least monitor the package and occasionally
change the roll stock of film. If the effort is to reduce employee cost, this
approach is especially questionable in a section of production line that
requires one or two individuals at most. While a machine does have the
possibility of packaging items faster, at this point in time, the output of
mills does not exceed the ability of one or two packagers to wrap a load of
lumber before the next load is run through the line. In the cases where lines
have temporary increases in output where two employees are having difficulty
keeping up with production in packaging stations, a third employee can be added
temporarily for assistance…I have never seen more than two on a packaging line
for any long period of time. Of course a machine will take the place of one or
two employees, but at what cost? Let’s look further.
The plastic becomes a dedicated necessity. With automated
packaging machines, the plastic needed is only able to be purchased from a
limited number (if not one) plastic company. In nearly all cases, the automated
machine sold to a mill is done so by a plastic company rather than a machine
company. Why? The goal is to require mills to rely solely on the plastic
company for their plastic source. It seems extremely difficult to effectively
analyze the pay-off on the purchase of a new machine without considering the
plastic costs that parallel machine use; plastic prices will never be guaranteed
beyond a year (at the very most) due to the reliance on oil prices. Who is to
say the plastic company selling the film with the automated wrapper will not ‘tell
you’ the price of film has gone up and your new price is substantially higher.
Upon purchasing the machine and working it into your line, you now have an
absolute need of the associated poly to run on that machine. Usually this is
extruded polyethylene, from a single supplier. What is to stop you from being
overpriced on your film after purchasing the machine?
The most important issue with adding an automated wrapper to your
production line is related to both quality of packaging and machine reliability.
The most important issue with adding an automated wrapper to
your production line is related to both quality of packaging and machine
reliability. These are two areas which
need heavy consideration. Will the machine have consistency in packaging
quality? What happens when the package fails to apply properly (how many
variables are inputs to the completion of a solid package)? When the production
line is going full speed and then the packaging line goes down, what are the effects
(a traffic jam of lumber)? These are all risks that need to be weighed against
the constants of two packaging gurus named something like Jack and John, who
happened to be equipped with staple guns and a good sense of humor. The stock
film also does not allow for properly wrapping variable changes to board feet
or pallet width changes in-line.
We are not suggesting that automated packaging systems are not a good idea for the lumber and wood industries. They are a great idea. They just have not worked in the past and they are expensive compared to the associated risk to productivity/output. Rarely does one want to be 'stuck' with a single supplier without the option of going somewhere else for plastic roll stock. No one wants a "down" line of production due to a packaging machine failure or malfunction...can you imagine your customers not receiving their order because the new packaging machine that was supposed to be a more efficient way to package stopped working correctly...
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