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Saw filing 101: Planning for an AI-driven future

Today’s saw filing rooms are starting to integrate equipment and software with limited artificial intelligence (AI). Some have even fully embraced machine learning and robotics. In my area, however, most mills are relying on what I like to call “Head Saw Filer Intelligence” (HSFI – the vast knowledge base that will shape future AI systems. The issue with HSFIs is that there simply aren’t enough skilled professionals to meet the demand. As this shortage grows, filing rooms will increasingly turn to AI-powered machines to fill the gap. AI has many potential applications beyond the filing room, and it’s only a matter of time before we see significant advancements across our industry.

When I first began my career in sawmilling years ago, there was no shortage of labor, and plenty of people I considered career sawmillers – sawyers, millwrights, and saw filers – were readily available. Back then, many employees were eager to learn new skills and move between roles within the mill, increasing their value to the mill owner. Saw filers, in particular, often learned their craft from a family member. 

Occasionally, someone with a natural interest would catch the attention of a head filer, who would then invest time in training them, despite the lack of formal “saw filing schools.” This is where AI, in my view, could play a pivotal role in the future of our profession. By capturing the expertise of these seasoned head filers, millwrights, and sawyers, we could create programs that not only retain their knowledge but also develop more efficient ways to build and maintain saws and cutting tools.

The need for AI integration

It’s fun for us older guys to reminisce, but to keep the industry moving forward, we need to apply the lessons we’ve learned to invest in its future. When it comes to AI, it’s important to remember that the goal is not to replace the human workforce. Nor do we want technology that ties up a mill with expensive, hard-to-find equipment that only a handful of people can service. Like any new advancement, adopting AI requires careful planning. Can the AI system be bypassed if there’s an issue, or will it shut down the entire production line? Are the CPUs, GPUs, TPUs, and other parts readily available? How easy is it to find qualified service technicians? In the past decade, we’ve seen constant innovations in technology and how lumber is manufactured – these rapid changes are making some hesitant to invest in newer AI equipment. Much like smartphones that are upgraded every six months to a year, how long will this new technology be supported? The COVID crisis, if it taught us anything, showed us how the inability to source parts and services can grind an entire industry to a halt.

AI as an assistant

Manufacturers of saw sharpeners have done a commendable job incorporating both robotics and machine learning into their equipment. Now comes the question of AI. I like to imagine an AI assistant – one that can monitor every step in saw repair. 

From my experience working with saw filers, I’ve noticed a recurring issue where critical steps in the process are either rushed or overlooked entirely. An AI assistant, programmed with the head saw filer’s knowledge, could help address this. The apprentice saw filer would be guided by the AI through each stage of saw repair, with the assistant walking them through the steps and answering questions along the way. Questions could range from “What’s the hook angle on the #1 edger saw?” to “When should I change the grinding wheel?” The head saw filer would then be able to monitor the apprentice’s progress and evaluate how well they performed their tasks. As head saw filers or corporate filers move between mills within the same company, they could update and fine-tune the AI’s knowledge base. I think I saw something like this on an episode of The Jetsons – for those reminiscing about your filing days! And for you younger filers, you can catch it on YouTube.

Paul Smith is a saw filing consultant and founder of Smith Sawmill Service, now part of Comact. You can reach him at paul.smith@bidgroup.ca.