OJT Process - Eclipse Training Solutions...

Drop-Trimmer On-Job Training Process Others set their standards by what you do every day!

Reviewed/Revised11/13/2015 Cottage Grove

OJT Process

Who is required to complete this packet: New to this position Cross Training

Staying Qualified on a Job: Team Member must

o enter time for job performed when working (enter task profile ID)

o and inform their Team Leader Role and Responsibility

Team Leader: Following through with each employee

Trainer: Ensure OJT checklist requirements are met

OJT Facilitator: Recordkeeping and facilitating information

Safety Steward: Cover all aspects of training on Safety Steward Guidelines

Learn and use Safe Start methods to ensure your safety



Team Leader & Trainer Expectations

Team leader: Be a partner with the trainer. Discuss the job and training aspects with trainer BEFORE the trainee arrives:

o Make sure that trainer understands the OJT and the Intrac module. o Review their expectations with them.

Talk about some of the more difficult parts of the job: o What are some common and uncommon upset conditions?

Talk about some of the misconceptions that people have about the job: o For instance, the difference between learning a job and becoming an expert at your job. o Let the trainer know how important the training is…for safety, for production, for

Cottage Grove. “If it’s worth doing it’s worth doing right.” Let trainer know that the team leader will be talking with them throughout the training:

o To see what the trainer thinks is going well. o Where the trainee might need help. o DO NOT hurry the process. o What ideas do you have that would help the next trainer?

Let the trainer know how important their contribution is to the team and that they are part of the success of Cottage Grove.

While training, review the checklist and the trainer’s notes: o What is missing from the packet? o What is not current? o There should be ample notes in the completed checklist to show a true evaluation of the

training process. Trainer:

Read through the process before training begins. Talk with the team leader and safety steward about concerns that may come up during training. If trainer is not sure the trainee is ready, talk with the team leader about this. Give the trainee the necessary time to learn the job – no rush. Realize not everyone is the “greatest” right off the bat. You can be a good operator in a couple

of weeks, but it takes time to be a great operator. No exceptions. Be patient. All areas of the OJT must be reviewed and completed with the trainee. Read all the pages…make notes as you go through the process.

Stress the importance of knowing your up and down stream customers – how you can work with them for the benefit of all.



Mill B – Job Expectations and Job Scope

Expectations:

Perform your job in a safe, conscientious manner abiding by all company policies and procedures.

Attendance – be on the job when whistle blows with proper PPE. Take breaks within the handyperson’s schedule. Keep your work area clean. Make sure all tools are sharp and stored properly. Notify handyperson when need for

replacement. Train other operators as required and keep up with all training – Intrac, JSAs. Communicate any operational events that may affect safety or production to appropriate persons

including other shifts. Teamwork – work and communicate well with others. Treat others with dignity and respect and

pay attention to up-stream and down-stream customers. Once qualified, operators must maintain the required production levels.

Drop Operator:

Provide a safe, smooth, continuous flow of boards from the Board Edger/Gang Edger outfeed to the Trimmer Operator.

Watch the monitors for specified sensitive areas in the lumber flow. Handle the boards only when needed. Discard useless boards and edgings safely to the chipper conveyor. Straighten cross-ups and lumber jams. Safely and proficiently operate the Trimmer. Run long and incline infeed chains to maximum lug fill. Work safely and productively with Sorter Operator to clear cross-ups. This is not a definitive list of all required duties.



Trimmer Operator: Feed one board per lug. Make sure all line-up fences and rolls are operational. Safely process lumber through trimmer to sorter. Watch monitors for specified sensitive areas in the lumber flow. Handle the boards only when needed. Calibrate and clean trimmer scanner as well as make a story board when needed. Safely and proficiently change trimmer saws. Straighten cross-ups and lumber jams on all transfers. Safely and proficiently run the Drop position. Work safely and productively with Drop Operator. Work safely and productively with Sorter Operator to clear cross-ups. This is not a definitive list of all required duties.

Trainee Date Team Leader Date

For Employee’s File



3 Tier Training Plan –

Trainer

Trainee

Team Leader

• Tier One –

Trainee reviews OJT, completes special training for job, Intrac training, memorize machine center components, learn LOTOT for job.

Trainee observes trainer doing job

Complete blank machine center maps to demonstrate component knowledge

Initials

Initials

Initials

• Tier Two –

Trainee safely performs job tasks for short periods of time

Initials

Initials

Initials

• Tier Three –

Trainer can leave trainee for short periods o Trainer must have radio or be close by

Trainee safely performs job tasks for at production levels.

Initials

Initials

Initials

Before beginning each new Tier: Team Leader, Trainer and Trainee will discuss expectations and initial appropriate column. NOTE: Red Hats are required to partner with another person when locking out during their 60 Day period.



Qualification Checklist

Trainee Name: Blank Maps Completed: Drop and Trimmer Date Training Started: Date Qualified: Trainer Signature: 2nd Trainer Signature: Planer Operator Signature: Safety Steward Signature: Purpose of Training:

� Bid Job � Cross Training Date completed: Date completed: � Pinkpak/CG Seniority / � Intrac Completed 2X

� ESC � Safety Intrac current

All Safety and OJT requirements for this job have been successfully completed.

Teamleader: Date

Operations Manager: Date:

OJT Facilitator:

Safety Intrac Modules up to date

Machine Center Module completed X2 & Checklist entered into Intrac

CG Seniority Map



On-Job Training -– 120 hours minimum training time required Intrac Training / Specialized Training – First Week � All Safety Intrac Modules must be up to date Machine Center Intrac Module must be completed

before moving to next step. Specialized training must be completed now:

�2 hours with the finish planer operator

� Hoist Intrac

� Review RADAR+ What does it stand for? How do I use it? Training –:

�LOTOT Training at MCC locations Demonstrate area & task specific lockouts for job center Demonstrate knowledge of how to read a LOTOT procedure � Blank component maps - Learn component names – be able to fill-in blank maps

Begin machine center job training.

� Begin On-Job Checklist – Mark corrections for needed updates/changes. Job Training (Second & Third Weeks of Job Training)

� Additional training 1 week minimum with 2nd full time operator (prefer on another shift)

� Work with Up & Down Stream Customers – minimum of 4 hour each (Print below) Sorter : Gang & Board Edger: Quad:

� Complete Intrac job training module for the second time. � Please note any corrections that need to be made to the Intrac Module and give notes to OJT

Facilitator with your checklist packet.



Learn more about the Job Area Trades People OJT with Operator –

Mechanical

Electrical

Filing

• Walk the flow of material from infeed to out feed. Explain devices.

• Communicate past mechanical/electrical/filing downtime events

• Discuss routine maintenance schedules and why.

• Discussion of areas that the operator can assist trades people.

• Develop a plan for relaying critical information/questions to route owner.

• When do I call a filer? Why do I call a filer?

N/A N/A

• What information needs to be communicated to engineering when using a radio for a reliability event?

• Clean-up expectations.

• Hot Works Expectations.

N/A N/A

• Downtime expectations (if machine is down during shift what information will trades people need?)

Route Owner Mechanical: Route Owner Electrical: Shift Saw Filer:



Final Check Off Trainer, Team Leader, Safety Steward and OJT Facilitator confirm all requirements are met: Evaluate:

� Checklist have been completed

� Trainee describes the flow of the area

� Trainee demonstrates safety requirements

� Trainee demonstrates willingness to accept directions

� Comments/Concerns from engineering, trainers, Safety Stewards, Team Leader



Questions / Observations / Suggestions: ________________________________________________________________________________

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Feedback: ________________________________________________________________________________

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08/2017 Cottage Grove

On-Job Training Checklists

The following procedures will be demonstrated by your Trainer. When you have had time to practice, your Trainer will ask you to perform each item and will check you off. If you don't understand any item, ask the Trainer to repeat the demonstration or explanation. PPE

DEMO

CHECK

• Identify personal protective equipment required:

Hard hat

Safety boots

Hearing protection

Safety glasses

Disposable Respirator (Voluntary Use Form)

Goggles when using an air hose

Gloves – appropriate for the task

• Safe Start – These four states….:

Rushing

Frustration

Fatigue

Complacency

Can cause or contribute to these critical errors….

Eyes not on Task

Mind not on Task

Line-of-Fire

Balance/Traction/Grip

…which increase the risk of injury.



First Aid/Emergency Response/Environmental

DEMO

CHECK

• Identify location of the following:

First Aid kits

Bloodborne Pathogen kits

Eye wash stations

Fire extinguishers, Fire Alarms, Plant Evacuation Alarm

• Locate assembly areas:

Primary assembly area — parking lot at mill b outfeed.

Secondary assembly area — near merch tower.

• Identify appropriate emergency response for your area:

First Aid:

- Call a First Responder – know First Responders for your area and shift.

Imminent danger to you or others:

- Hit the EMERGENCY STOP button on operator console.

Help Needed Whistle:

- Safely shut down machine center and listen for instruction from the Team Leader.

Fire Alarm — Evacuation:

- Safely shut down machine center and evacuate to assembly area.

Plant Evacuation Alarm — Evacuation:

Call 9-911 as appropriate in any emergency.

• Identify spill response:

Ensure personal safety and the safety of those around you.

Contain and stop the leak if possible.

Call for help (your Team Leader and/or 2U).

Notify your Team Leader if you have not already done so.



First Aid/Emergency Response/Environmental (cont.)

DEMO

CHECK

• Locate SDS for materials you may be exposed to:

Access through 3E system electronically.

Hard copy available from Environmental Manager.

• Locate the satellite station for aerosol cans.

RADAR+ & SafeStart

• Use RADAR+ Assessment process for any stop in the flow or process (upset condition):

What State am I in?

Complete RADAR+ form and leave on the RADAR+ clipboard (the Teamleader will pick these up throughout the week).

Identify potential hazards.

Turn in completed RADAR+ to your Team Leader.

Safe Work Practices

• Demonstrate safe lifting procedures

Beware of Complacency

Lift with your legs.

Maintain firm footing.

Keep your back straight.

Keep the load close to your body.

Watch for pinch points as you set down a load.

Ask for assistance as necessary. Dr Greg appointments can be used for on or off the job advice. Let your Team Leader know you would like an appointment.



Safe Work Practices- continued

DEMO

CHECK

• Demonstrate safe use of tools (e.g., picaroons and pike poles):

Eyes on Task & Mind on Task before using tools

Check tool condition before use — no cracked or broken handles, points sharp.

Replace worn or damaged tools.

Keep tool clear of obstructions (e.g., walls, handrails, consoles, wood boxes) while using it.

Ensure you can hold the entire weight of the tool while using it.

Maintain stance and balance while using a long pike pole.

• Demonstrate safe use of an air hose: Beware of Line of Fire -

Wear goggles (dust mask optional).

o Store goggles in a closeable container such as a zip lock baggie

Ensure air nozzle has relief holes.

Maintain a firm grip on hose.

Keep hose clear of moving equipment.

Never use an air hose to clean off yourself or your clothing.

Never blow pressurized air towards others.

Heating and Cooling • Heaters:

Pre-Use: Clean off to prevent eye irritation from blowing dust

Be aware of fire hazards (you’re generating a lot of heat) in line of heat stream

Turn heaters off at the end of shift

Kerosene heaters require a Hot Works Permit (see your Team Leader if you have questions)

• Fans:

Clean off to prevent eye irritation from blowing dust.

Turn off fans at the end of shift



Lumber Handling – Eyes & Mind On Task

DEMO

CHECK

• Lugged and Even-Ending Rolls Stop IS required anytime a board needs moved or maneuvered on lugged

chains or even ending rolls by hand or with a tool.

• Unlugged Chains Stop is required when removing a board or chunk >8’

• Unscrambler Stopping is required when using a tool in the unscrambler. LOTOT is required to enter the unscrambler. LOTOT before putting your

hand or any part of your body into the unscrambler.

• Pinch points:

Look for Line-of-Fire potential

Between lumber, components and lumber, and components themselves.

Picaroons and Pike Poles

• Picaroons and Pike Poles

Replace tools that are in poor condition

Locate tool crib for sharp & dull picaroons

Spikes must be sharp and handles have no sharp or jagged edges or spurs

• Do not rest a tool handle on an object such as wood box, handrails, operator consoles, etc while using.

• When tool is in use, you must be able to hold the entire weight of the tool as you are using it; this will prevent the tool from bouncing and striking the user

Proper stance – distribute your weight

Be aware of your surroundings

• SELF-TRIGGER on Ergonomics Be aware of your lifting capabilities – the longer the pike pole the more awkward a position you may put yourself into



Storage of Tools

DEMO

CHECK

• Store tools in the designated holders when not in use. Talk to your team leader if you need tool holders. Tools not in good condition should be taken out of service.

Identify Hazards and Safe Work Procedures DEMO

CHECK

What state are you in?

What critical errors can increase the risk of injury?

Use caution on all stairs and walkways: o Watch for debris build-ups

o Watch for wet or slippery areas

o Use three point contact at all times

• Watch for low overhead clearance areas when cleaning up:

Position yourself to avoid twisting your body

Ensure materials‚ i.e.‚ tools or waste receptacles are used or positioned safely

• Identify hazards near or under operating equipment:

Do not enter areas without following lock-out procedures

• Clear jams in conveyors safely:

Never enter a conveyor without following lock-out procedures

If a tool is caught in a moving conveyor, let it go

Push material in the direction of the belt movement



LOTOT (cont.) Rushing, Frustration, Fatigue and complacency can lead to Mind Not on Task

DEMO

CHECK

• Locate the LOTOT Procedures Notebook:

Review procedures.

• Locate the Machine Center Map:

Identify machine center components.

Review the process flow.

• Demonstrate how to safely isolate a lockout switch or device:

Visually verify that MCC buckets doors are secure; arrows on panel screws are facing away from bucket

Stand to one side of a bucket with your face turned away and pull handle with your hand.

Watch for pinch points when depressing air dump valves

• Describe LOTOT procedures for unscheduled downtime during normal operational hours including pre-shift:

Minimum lockout includes the component you are working on/in, and any component directly up or downstream (above and below).

• Describe LOTOT procedures for scheduled downtime (shutdowns or “windows”) and unscheduled downtimes (during normal operational hours including pre-shift):

o Scheduled downtime: Full area lockout is required – see Notebook for procedure.

o Unscheduled downtime: Lockout component you are working on/in and any component directly up and downstream – see Notebook for procedure.



LOTOT (cont.) Rushing, Frustration, Fatigue and complacency can lead to Mind

Not on Task

DEMO

CHECK

• Describe procedures to follow if you need to enter a locked out area once work has begun:

Verify that all components have been locked out.

Check with the responsible person that all equipment was tested after being locked out.

Add your lock to the multi-lock device(s).

• Describe procedures to follow if you need to lock out additional components:

Ask everyone to clear the lockout area and remove their locks.

Perform full LOTOT procedures for all equipment to be locked out.

• Identify hazards near or under operating equipment:

Do not enter areas without following lock-out procedures

What state are you in?

What critical errors can increase the risk of injury?



World Class Housekeeping – 5S

Take Pride in Your Workplace! Housekeeping – YOU HAVE TIME!

DEMO

CHECK

Your workstation o Empty trash

Drop off at nearest Trash box o Empty recycle

Drop off at nearest blue recycle bin o Remove all personal items at end of shift

Take home or store in your locker

Refrigerator – this is a privilege o Keep refrigerator clean

Clean any spills (even if they are not yours) o Remove all items at end of your work week o Wipe down shelves o Wipe down outside of refrigerator

Returnable Bottles o Bags can be taken to the millwright shop – to the right as you enter coming

from the mill or merch line FYI – Bottles are a large part of the ACTivity Club funding.

Operator Lockers o Keep lockers clean

Name plates on lockers o Do not store items on top of lockers o No “decorating” outside of locker – no stickers

Cabinets o Should be labeled o Items stored neatly inside o Limit items –

remove all unused items do not overstock

o No storage on top of cabinets



Housekeeping – YOU HAVE TIME!

DEMO

CHECK

Flammable Lockers o All flammable items (degreaser, spray paint, oil, gasoline) should be stored

in a flammable locker o Only flammable items should be stored in flammable lockers o Limit inventory of each item (do not store 6 when only 1 is used per

month) o Wipe down outside of locker to remove buildup of dirt and grim

Everything should have a designated home o Nothing leaning against a wall or in a corner o Nothing laying on top of a cabinet or shelf

Tools should be stored in tool holders o No leaning against a wall or in a corner

Sawzalls o A sawzall holster for proper storage – never laid out with blade in and

battery on or plugged in.

Hose reels (Water/Air/Welding) o Should be rolled up after each use (potential trip hazard) o Reels should be labeled



Work Station Components and Controls

• Locate and identify location and function of the following trim line infeed components:

(Board Edger) Slow Down Belt

Landing Table

Drop Scraper Clean-up Chain

From the Gang

o Gang Infeed Roll Case

o Gang Outfeed Roll Case

Long Transfer

Right Side Board Separator:

o Sideboard Transfer Table (Transfer Deck)

o SB Outfeed Belt #1

o SB Outfeed Belt #2

o Slow Down Roll (between Belt #2 & Landing Table)

o Landing Table (Over Long Table to Unscrambler)

o Decline Arms and Belts

Incline Transfer

Unscrambler

Speed-up Chains

Spiral Ending Rolls

Drop Storage Transfer

Trash Gate

Trimmer Chipper Vibrating Conveyor

Lug Loader Transfer #1

Lug Loader Transfer #2

Comact Lug Loader - Long and Short Transfers

Comact Holdback Arms

Lug Loader with Grabbers

Air Dump Lockout Valve for Comact Holdback Arms



Components and Controls (cont.)

DEMO

CHECK

Scanner Lug Chain

Scanner Even End Rolls

Scanner Lug Chain

Scanner

o Laser Warning Light

o Monitor

Laser Key Lock Air Dump Lockout Valve for:

o Drop Trash Gate

o Comact Holdback Arms

o Positioning Fence

Trimmer Lug Chain Tensioners

Positioning Lug Chain

Positioning Lug Chain Even Ending Rolls

Positioning Fence

Trimmer Lug Chain

Trim-ends Belt

Trimmer cleanup Belt (behind)

Trimmer Outfeed Reman Belt

Trimmer Box o Saw change walkway

Smart Gate o Smart gate walkway

Air Dump Lockout Valve for Smart Gate

Even End Lug Chain

Even End Lug Chain Even End Rolls

Speedup Lug Chain

Askew Board Detector o Askew Reset Button

Sorter Infeed Speedup Chain

Air Dump Lockout Valve for Sorter Diverter Arms



Components and Controls (cont.)

DEMO

CHECK

• Identify location and function of the following trimmer components:

Trimmer/Sorter Line VFD

o Trimmer Lug Chain

o Even End Lug Chain

o Speedup Lug Chain

o Sorter Infeed Speedup Chain

o Sorter C Hook Chain

o Even End Rolls

Scanner

Positioning Lug Chain

Even End Lug Chain

Length photo cells

Lift skids

Live fence

Trim saws

Smart gate sections

Askew photo cells

Components

• Demonstrate where you lockout each of these components

• Explain what it mean when components are interlocked

• Demonstrate how you test the components that are interlocked



Work Station Operation

Eyes on Task & Mind on Task before starting!! Perform Pre-start Checks and Start Up

DEMO

CHECK

• Make sure all guards are in place, gates closed and that no tools or other equipment have been left around the area.

Perform Pre-Start Checks

• Check infeed areas for cross-ups, personnel in the area.

• Check for obvious signs of equipment damage.

• Check for lugs out of time.

• Check to make sure from scanner lug chain through the trimmer is on the timing marks.

• Check trimmer outfeed area to ensure area is clear.

• Check to ensure sorter is ready to start up.

Start Up Trim Line

• Ensure ALL FREEZE buttons are up.

• Start up trim saws.

• Start up sorter drive.

• Start up infeed transfers and belts.

• Set controls to AUTO for automatic operation.



Shut Down

DEMO

CHECK

• Ensure trim saws are clear.

• Put trimmer on timing mark.

• Shut down infeed transfers and belts.

• Shut down sorter drive.

• Shut down trim saws.

Operate Drop Sorter Work Station

• Monitor trim line infeed:

Notify Edger Operators if required to shut down board edger infeed.

Respond to cross-ups and jams at edger outfeed or on infeed transfers.

Clear jams at unscrambler.

• Operate drop gate:

Use gate to route non-recoverable pieces to chipper (pieces that will not make minimum of 2x4x8').

Maintain flow to trimmer.

Monitor quality of pieces and notify team leader and saw filers of quality control problems.



Operate Trimmer Work Station

DEMO

CHECK

Trimmer Scanner • The scanner reads the board and attaches a specific solution to the lug space.

The computer then follows that specific lug space to the trim saws, tipple gates, sorter c-hooks and sorter kickers

• The trim saws will complete the scanner solution for the lug space by dropping the required saw or saws.

• The tipple gates will open (one or more) as required by the solution for the lug space.

• The sorter c-hook will go to the bin as required by the solution for the lug space.

• The kickers will kick off the board of that specific lug space as directed by the solution back at the trimmer scanner.

If you put a board into a lug space (after the scanner), the scanner will have a “no solution”. Saws will not rise or lower will not rise for that space.

This could result in a crash at the trimmer, tipples or sorter.



(Lazy) Trimmer Saws – how they work This saw box uses lazy saws.

That means that at the beginning of shift all saws (not including the zero saw) start in the up position.

Once the scanner reads a lug and tells a saw to drop to make a cut, it stays down until the scanner tells the saw to raise.

Saws stay in the down position until a specific lug space does not need cut by that saw – it then rises to the up position.

EXAMPLE The scanner reads the first lug space that passes under the scanner and finds a

20’ board. The scanner tells the trimmer to drop the 10’saw in that lug space that happens

to contain the 20’ board. Once that lug space leaves the trimmer the 10’ saws stays in the down

position.

The 10’ saw stays down.

The solution also told the far end tipples to rise, sending the newly created board to the board edger.

The solutions told the c-hook to take the remaining board to a specific bin and at that bin the kicker will kick the board into place.

If the lug space behind the 20’ board is empty the 16’ saw will stay in the down position until given a new solution.

If you put a 16’ board into that empty lug space after the scanner the 10’ saw is still in the down position.

The board gets cut leaving a 10’ board and a 6’ board.

The tipples do not rise to drop out the 6’ board. The 12’ and 14’ saws do not drop to send the 6’ piece into the trash belt.

UPSET – a 6’ piece of wood is riding out to the sorter to drop where or it skews and jams into the c-hooks, or skews and causes a chain to break.



Operate Trimmer Work Station

DEMO

CHECK

• Monitor lug loader operation:

Ensure boards are loading one-at-a-time.

Separate doubled-up pieces.

Clean photo eyes as required.

• Monitor pieces as they move through scanner:

Pieces straight on lugs.

Non-recoverable pieces sorted out.

Boards moving to fence at even-ending rolls.

Monitor operator interface/reader board and alert Team Leader or PFC:

Watch for/respond to error messages. (thin, narrow, etc..)

Check percentages for slash, reman, trim loss, etc. frequently and compare to the control sheet in PLC room. (watch computer screen at the work station and watch the reader board).

• Respond to cross-ups and auto shut downs:

Clear cross-ups at sorter infeed (askew photo cell shuts down operation).

Communicate with Sorter Operator when sorter drive shuts down — sorter alarm.



Story Board SOP

DEMO

CHECK



Calibrate Scanner Every Shift:

Clean Lasers and PlanView every shift break:

DEMO

CHECK

Lock out scanner Lasers by turning off the key. (red lamp turns off)

Install the calibration bar on the chains over the lasers – slide calibration bar on 2 inch side only, and roll into place over the lasers.

(Do Not slide calibration bar on the 4” flat calibrating surface, sliding removes the reflecting paint.)

Align calibration bar over Laser Zero, Cal bar should also cover 87, the Cal bar is marked to show where to place it on chain #1.

Turn the key back on: (red lamp turns back on) The key powers up the lasers– do not calibrate with the key in the OFF position. Key MUST be ON and the red lamp must be ON.

Look at Operators Screen

Select Diagnostics screen “ Transverse Scanner Diagnostics” Select View Sensors Select View Graph; Start and Stop Read Select View Text

Select Calibrate

Read the thickness with “READ” button

Look for thickness numbers between 2.00 and 2.030 If the calibration is below or above move the Cal Bar and read again. (We prefer

2.010 to 2.020.)

Press SAVE button, Close before pressing READ button again

Return Calibration Bar to hangers

Operators, DO NOT change the Cal Bar thickness number it is set to 2.015 • 11-21-2013



Maintain Quality Control

DEMO

CHECK

• Identify the following manufacturing defects and the source(s) of the defects:

Saw snake

Feed roll marking

Chipper knife marks

Over or undersize pieces

Saw step (offset)

Respond to Operator Interface Alarm Message

• Excessive reman:

Check boards going back to reman to see if correct decision is being made.

Call the team leader

If correct decisions are being made, inform Board Edger Operator of problems.

If incorrect decisions are being made, contact supervisor and assist with system check.

• Excessive slash:

Watch boards being slashed to determine if correct solution is being made.

Call the team leader

If incorrect decision, assist with system check.

• Excessive too narrow/thin boards detected:

Alert the team leader.

If necessary, assist with system check.

• Re-set unscrambler/incline:

Attempt at Drop HMI (touch screen) or re-set panels at MCC.

Re-start equipment.



Change Saws at Trimmer

Saw Change

DEMO

CHECK

• Follow LOTOT procedure.

• You will need to come-along up the ladder for the 10’ and 18’ saws when changing those saws.

• Change saws:

Wear arm guards and cut-resistant gloves while handling saws.

• Remove your locks.

Timing Mark Procedure

Timing marks are painted black with silver line indicating the leading edge of the lug should be on this line before starting the Timing Mark Procedure. Locate all timing marks

a. Scanner Lug Chain ( ½” forward or back) b. Positioning Lug Chain ( ½” forward or back) c. Trimmer Lug Chain ( ½” forward or back) d. Even End Lug Chain e. Speed-up Chain f. Sorter – beginning of J Hooks (painted silver)

• The sorter and trim line is interconnected – when the machine is set to a timing mark all of the chains must be in the correct location or the possibility of a crash greatly increases.



Drop/Trimmer Standard Operating Procedures

Establish Optimum Flow

CHECK

The objective of this document is to establish operating guidelines that will assist with the safe, reliable operation of the Drop / Trimmer resulting in optimum safe production and efficiency in the sawmill.

• Demonstrate using the monitors and adjusting to the changing conditions in the sawmill.

RADAR+ EXPECTATIONS

CHECK

All affected employees actively participate in risk assessment by completing the RADAR+ form.

Complete hazard assessment on the back of the RADAR+ form. There should be ample notes on the RADAR+ form to show a true evaluation and

explanation.

Any unplanned or unscheduled lock out event, any task new or unfamiliar to an individual, and any upset condition not addressed in the JSA/SOP, deserves a written RADAR+.

Hazard (Webster): to expose to chance, to put in danger of loss or injury, a source of danger. The potential for danger is imminent. A Hazard ID situation needs to be:

Immediately taken care by yourself or You communicate the problem to someone who can make sure the situation is taken care of immediately. (Team Leader, millwright, etc).



Stopping Quad Outfeed Process (Right Board Separator to Decline Arms)

CHECK

Soft Stop – This is the only option (No Hard Stop) Low Priority Quad Stop - HMI round button (Circle on main operator HMI screen)

Stops the AR Conveyor and clears out the line. Once the line is clear the Outfeed Belts and Landing Table/Decline Arms stop

Enable outfeed by pressing button again

This is not an Emergency Stop

Stopping Quad/Gang/Board Edger

CHECK

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Respond to Problems

Location: Drop Problem: Skew on the LongTransfer to Drop

CHECK

The Gang Operator has a monitor view of the 2nd Transfer to the Trimmer.

When working the Drop position periodically turn to see if there is skewed lumber on the Long Transfer to the Trimmer.

Listen to the intercom for warnings from the Gang Operator that there is skewed lumber on the Long Transfer.

If you see skewed lumber, or if you hear a warning from the Gang Operator, look at and assess the severity of the skew. If the skew is likely to cause problems with the orientation of the lumber on the Incline Transfer or in the Unscrambler, straighten the skew.

If possible, use the chains and the weight of the wood to straighten the skew. If you run skewed boards up next to boards that are straight and stationary, the skewed boards may straighten.

If you are not able to straighten the skew using the chains, stop the Long Transfer.

From the floor, using pike poles and picaroons, straighten the lumber. What is behind you? What will your pike poles hit? Footing? Pulling? Pushing?

If you are not able to easily and quickly straighten the lumber from the floor, prepare to get on the table by filling out a RADAR+ form and completing LOTOT.

LOTOT, get on the table, and straighten the lumber.

When the jam is cleared, unlock, and resume operating.

Skews sometimes occur as a result of a chain off the sprocket. Look at the sprockets on the transfer table. If a chain is off the sprocket blow 4 whistles for 2M. Clear lumber off the transfer so 2M can move the chain into position.



Location: Drop

Problem: Skew on the Incline Transfer to Unscrambler

CHECK

There is a mirror mounted on the wall adjacent to the 2nd Transfer to the Trimmer mounted under the clock. The mirror is angled to give the Drop Operator a view of the Incline Transfer to the Unscrambler. A monitor view of the Incline Transfer to the Unscrambler is not available to the Drop or Trimmer Operators. The Gang Operator has a monitor view of the Incline Transfer to the Unscrambler.

When working the Drop position use the mirror mounted on the wall beneath the reader board to see the orientation of the lumber on the Incline Transfer to the Unscrambler.

Listen to the intercom for warnings from the Gang Operator that there is skewed lumber on the Incline to the Unscrambler.

If you see skewed lumber, or if you hear a warning from the Gang Operator, look at and assess the severity of the skew. If the skew is likely to cause problems with the orientation of the lumber in the Unscrambler, stop the Incline Transfer.

Standing on the floor, using pike poles and picaroons, straighten the lumber.

If you are not able to straighten the lumber from the floor, prepare to get on the table by filling out a RADAR+ form.


When the jam is cleared, unlock, and resume operating.

Skews sometimes occur as a result of a chain off the sprocket. Look at the sprockets on the transfer table. If a chain is off the sprocket blow 4 whistles for 2M. Clear lumber off the transfer so 2M can move the chain into position.



Location: Drop Problem: Skew in the Unscrambler

CHECK

There is a mirror mounted on the wall adjacent to the Incline Transfer to the Unscrambler. The mirror is angled to give the Drop Operator a view of the V-notch in the Unscrambler.

When working the Drop position use the mirror mounted on the wall next to the Incline Transfer to see the orientation of the lumber in the Unscrambler.

Listen to the intercom for warnings from the Gang Operator that there is skewed lumber in the Unscrambler.

If you see skewed lumber, or if you hear a warning from the Gang Operator, look at and assess the severity and location of the skew.

If possible, stop the Incline Transfer or reverse it so that the flow of lumber into the Unscrambler notch will stop. Continue running the unscrambler until the skewed board(s) fall in place in the Unscrambler V-notch.

If skewed boards are traveling up the Unscrambler in a vertical position use caution. Do not operate the unscrambler so that vertical boards strike the lights, or become airborne.

If the skewed boards do not fall in place, stand on the catwalk and floor and use pike poles and picaroons to straighten the lumber.

If you are not able to straighten the lumber from the catwalk and floor, prepare to get on the table by filling out a RADAR+ form.


When the jam is cleared, unlock, turn the transfer chains on and resume operating.



Location: Drop Problem: Unscrambler Out of Time

CHECK

If boards are coming over the crest of the unscrambler in a skewed position, check the unscrambler chains to see if the lugs are out of time.

If you can safely do so, you can determine to run with the unscrambler out of time if it is the first or last chain. If one of the two middle chains are out time call 2M to put them in time.

If you feel it is unsafe to run with the unscrambler chains out of time, blow 4 whistles for 2M.

If there is wood in the unscrambler, run it out so 2M will be able to move the unscrambler lugs into position.

Location: Drop Problem: Working the Drop Position at the Spiral Ending Rolls and Drop

Storage Transfer Chain

CHECK

When working the Drop position always stay alert. Use your peripheral vision to spot skews upstream and downstream.

Be aware of volume and flow on the transfers and incline to the unscrambler.

Use the Auto and Manual on the transfers and incline to manage the flow of wood into the unscrambler. Operate in auto mode when volume builds to the point where chains are full and boards may overload the unscrambler or send an unacceptable number of stacked boards to the spiral rolls. Operate in Manual mode ONLY as needed. -- examples

Watch for boards that fall between the spiral rolls. Stop the unscrambler and spirals and either remove the boards with a picaroon or pike pole, or allow the board to fall into the Trimmer Chipper Conveyor.

Use the Spiral Ending Rolls in the Manual mode to manage the flow of boards on the spirals – use this method to straighten skewed boards that come over unscrambler.

Watch for skewed boards that may be directed towards you by the spiral rolls.



Location: Drop Problem: Working the Drop Position at the Spiral Ending Rolls and Drop

Storage Transfer Chain - continued

CHECK

Use tools or your hands to orient any skewed boards coming off the spirals.

Use tools to reach far away boards and pull them towards the even ending belt.

Orient the boards so that they slide onto the Board Feeder Backlog Chain in a straight position.

Use the Trash Gate to sort out material that should be chipped. Send bowed boards that will not fit under the scrapers to the Trimmer Chipper Conveyor. Try to let as many boards go through the scanner as you can to let the scanner make the decisions.

When using the Trash Gate be careful to feed the boards into the gate in a position parallel to the gate. Boards fed into the Drop gate in a skewed position can hang up in the gates. Hung-up boards can become a hazard when one end is up out of the drop gate and the other end is contacting the vibrating conveyor.

If boards are hung up in the Trash Gates, use the switch that holds the gate open and use pike poles or picaroons to free the board.

Un-stack boards that are doubled up, one on top of the other.

Monitor lumber quality as you work. If you see mismatch, snake, scratching, or any other quality defect call for saw filers or the Team Leader accordingly.



Location: Drop Problem: Plug in the Trimmer Chipper Conveyor

CHECK

While working, check the monitor view of the Trimmer Chipper Conveyor. Watch for jams that are developing.

If you see a jam starting to develop, blow three whistles for the Conveyor Chaser.

If you see a jam that is overflowing the conveyor, stop the conveyor until the Conveyor Chaser has cleared the jam.

Location: Drop Problem: Long Boards from Merch

Occasionally long boards (over 20’) come through the mill. They will not fit into the lug loader. Try to catch them early and use the sawzall to trim back the board.

Location: Trimmer Problem: Edgings from Board Edger

Put the edging in an empty lug to slash

Location: Trimmer Problem: Loader Not Properly Loading

Clean the eyes for the lug loader. (Scanner alarm) Call 2E to check camera (do not attempt to clean camera)



Location: Trimmer Problem: Trimmer Scanner Chain Area

CHECK

Bowed boards

Be alert bowed boards could come over rail

Boards pulled out to far

Stop and push the board in before it hangs up.

Double boards

Stop and separate the boards

Skewed boards before and after scanner

Stop and straighten the board(s)

Put them in the right lug space

Skewed board alarm

Check and fix all skews before starting sorter

Plan view error

Blow off scanner or clean

Double board detected

Sort board after the scanner

Blocked eye on scanner

Use air to blow off

Use pike pole to remove large pieces off the scanner

LOTOT to remove debris or clean the scanner.



Location: Trimmer Problem: Trimmer Scanner Chain Area - continued

CHECK

Scanner Chain out of time

Stop and call for a millwright to re-align the chains Clear chains of any lumber before millwrights arrive

Quality alarms (narrow and thin)

Notify Team Leader after you receive at most 2 to 3 narrow or thin board alarms Team Leader will let you know how quickly they prefer to know about the alarms

Timing marks

Be sure to put the trim line on the timing mark at lunch and the end of the shift.

At lunch check the timing marks and notify the millwrights if there is a problem

At the end of the shift the next operator can check the timing before starting

Location: Trimmer Problem: Long Board at Scanner

Board is too long to fit through the trim saws or it has been pushed out of the sorter line (photo eye is trigs Long Board alarm)

Correct the problem o Remove board o Cut off length of board o Or pull board back

Reset alarm on console Start up trim line



Location: Trimmer Problem: White Lug Chains and Fence Area

CHECK

Board stuck in live fence

Stop; use pike pole to free

If needed LOTOT to remove the board(s)

Bowed board over fence

Stop the trim line

Slide board back onto chains

Shear pin Alarm (shuts down line)

Press the RESET button if it does not reset -- Call millwright to check shear pin

Broken piece falls between chains

Use pike pole

If needed LOTOT to remove

Lug chains out of time Stop and call for millwright

Location: Trimmer Problem: Reman Chains 1- 6

Board edger notifies trimmer operator on intercom or trimmer operator may see the problem in the monitor

Trimmer operator goes to identify the problem

Could be a stick between the chains, or a board fallen between the chains, or a cross up.

Remove or straighten using a picaroon or a pike pole if necessary.



Location: Quad Outfeed Problem: Cant Fell Off Board Separator onto Transfer #5 or #6

CHECK

Use hand signals to the board edger operator position the cant over the jump roll case.

Use the air valve to raise the jump roll case

Pull the cant off using a picaroon. Ask for help in needed. Always inspect the tools, and test for a good hold before attempting to pull cants off.

Lower the jump roll case, and motion to the board edger operator that you are done.

Location: Trimmer Problem: Trimmer Saw Box

Steel lugs out of time

While running the trimmer watch the monitors closely for lugs out of time.

Also anytime you walk the trim line look for any lug chains out of time.

If you find a lug out of time, stop the trim line to prevent worse upsets or bad quality lumber.

Blow 4 whistles for the millwrights. Clear chains of any lumber

After the millwright re-aligns the lug chain, resume operating.

Will BE Op be able to see they’re done?



Location: Trimmer Problem: Trimmer Saw Box - continued

CHECK

Dull saw/broken saw/broken belt

Stop the trim line

Clear the Saw Box if possible.

LOTOT – follow procedures

Open the doors and assess the saws or belts

If the saw needs changed, (apply the turnbuckle and) LOTOT the air valve

Change out the bad saw(s).

Unlock the air and remove the turnbuckle (if it is being used)

Unlock everything else

If it is a belt, call 2M to repair belt

Resume operating



Location: Trimmer Problem: Clutch Pops Out

Clutch at Mill B Trimmer pops out -

B Trimmer Clutch button o Located on end of trimmer saw box o This button will lock the air break

To Re-Engage Trimmer Clutch o Push B Trimmer Clutch button for 3 seconds

o Have other operator advance sorter to the next timing mark This may have to be done more than once in order to re-engage the clutch If boards double-up before trim-box during the process, remove w/pike pole

Once clutch is engaged o Open tipple gates and run the lumber (from scanner thru to tipple gates) back to the

board edger o This is because the lumber will NOT be in the proper lug space and will go to the

wrong bin potentially causing major problems

Location: Reman Belt Problem: Cross-up / Trim End or board Stuck

Stop reman belt at Drop Console Once area is cleared belt is turned on at Drop Console and at the HMI screen (a

safety measure).



Location: Trimmer Problem: Tipples

Cross up in tipples

There are several things that can happen in the tipple gates, including cross

ups, broken air lines, and slow cylinders

Watch the monitors carefully and if you see a problem stop the trim line

Assess the area closely checking for the cause of the problem

After the problem is clear continue watching the monitors to make sure the root cause was solved. Call 2M if necessary

If it is a cross up, try to use the manual switches to operate the tipple arms and hand tools to clear cross ups

If necessary, prepare to enter the tipple gates by filling out a RADAR+

LOTOT the tipple gates according to procedure

Clear the cross up

Unlock and resume operating

Location: Trimmer Problem: Yellow Lug Chains

Cross up on yellow lug chains Use hand tools to clear cross ups



Location: Trimmer Problem: Skewed Board

CHECK

Skewed board at skew eyes If you get the alarm for a skewed board, walk to the skew eyes to assess the

situation

Use hand tools to fix any skewed boards

Push the reset button on the support beam for the skew eyes

Resume operating

Location: Sorter Problem: Sorter Overflows

The trimmer operator helps with overflows at the near end of the sorter as needed.



SAFETY STEWARD GUIDELINES �Who are your up and down stream customers? How can you affect them? �Tell me what specific PPE you are required to wear for this job? Why is it important? �RADAR+…When do you fill out one of these forms? Where are the forms? �Components section of OJT – show me where each of these components are located? �Where is the primary assembly? Secondary? What are a couple of routes to get there from here? �What are your responsibilities during an emergency? �Who are your shift Safety Stewards on this shift?…1st Responders? �Who are your Shop Stewards…Head Steward? Do you understand how they can help you? �Where are the closest First Aid boxes…Bloodborne Pathogen Kits? �SHOW me proper LOTOT… perform a mock area lock out together. You take the book and lead me through a mock lockout. �What are your safety questions? �If someone got hurt at this machine center what would be your guess about what happened? �What Safety recommendation do you have? Safety Steward – Initial here _________________ and sign on Qualification Page

OJT Process - Eclipse Training Solutions...

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