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3D – Layouts Digital Manufacturing

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  1. 3D – LayoutsDigital Manufacturing Nick Andreou, P. Eng. President, 3DL LLC www.3dlayouts.net

  2. 3DL From Virtual to Physical

  3. 3D - Layouts Simulate & Validate Industrial Facilities using Digital Manufacturing

  4. 3D - Layouts Agenda • Overview of Digital Manufacturing • Overview of 3DL LLC • Value of Digital Mfg / 3DL for: Industrial Facility Engineering Companies

  5. Requirements Flow down to the Details Validation Starts at the Details I. Overview of Digital Manufacturing Top Down - Bottom Up Methodology $ BusinessRequirements. Plant Synthesis Plant Models Area Models Detail Models

  6. The intersection of these three planes, is the NEW technical solution The intersection of these three planes, is the technical solution Digital Manufacturing Solutions Digital Product/ Tool Data Process -Std Processes -Simulation Facility -Plant Layout Alternative #1 Facility -Plant Layout

  7. Digital Manufacturing - WEB - Communication Click to link Click to link Simulate the Process Collaboration 3D Layouts Click to link Product & Equipment: Common in 3D Math

  8. Global Economy Asia Europe North America Africa South America Australia

  9. 3D - Layouts Agenda • Overview of Digital Manufacturing • Overview of 3DL LLC • Value of Digital Mfg / 3DL for Industrial Facility Engineering Companies

  10. II. Overview of 3DL • 3DL Background & Credentials • 3DL Capabilities & Services • 3DL Integration Services • 3DL Cost Advantage ----------

  11. II. Overview of 3DL • 3DL Background & Credentials 1.1 Engineering 1.2 Manufacturing 1.3 Construction 1.4 Information Technology 1.5 Project Management 1.6 Staff Credentials

  12. II. Overview of 3DL • 3DL Background & Credentials 1.1 Founder has 30 years with GM, developing Manufacturing Systems, Product Development, Project Management and IT. 1.2 Since 2007, 3DL has partnered with MHSI, to build Client Base and Digital Capabilities. 1.3 3DL has dedicated staff for 3D Layout projects and larger shared staff for Laser Scanning and Post Processing

  13. II. Overview of 3DL Invest for Integration, but Partner for Digital Mfg / Specialized Skills • 3DL Background & Credentials 1.4 3DL has partnering relationships with: • CAE companies • Niche Digital Mfg Companies • Larger staffing contractors • Mfg Eng companies, …to seamlessly handle any job regardless of size. 1.5 3DL’s offices are located in Rochester Hills, MI

  14. II. Overview of 3DL • 3DL Background & Credentials • 3DL Capabilities & Services • 3DL Integration Services • 3DL Cost Advantage ----------

  15. II. Overview of 3DL • 3DL Capabilities and Services 2.1 Digital Object Creation / Libraries 2.2 3D Layouts (convert from 2D or create new) 2.3 Laser Scanning  Point Cloud Processing 2.4 Reconciling Point Clouds to 3D Layouts 2.5 Managing File Size / Format / Layers / Standards 2.6 4D Interactive Time Line with 3D Visualization 2.7 3D Layout Coordination / Project Meetings 2.8 MHSI_Operations.net (Issue Mgmt, project tracking) --------

  16. II. Overview of 3DL • 3DL Background & Credentials • 3DL Capabilities & Services • 3DL Integration Services • 3DL Cost Advantage ----------

  17. II. Overview of 3DL • 3DL Integration Services 3.1 Disparate Design File Format Integration • AutoCad, Catia, UGS, SolidWorks, FactoryCad, etc 3.2 Mfg Simulation Services; Management • Through Put, Work-Cell Visualization, Human Models, Parametric Models, FEA 3.3 Laser Scanning Services  Point Cloud Processing 3.4 Collaboration / Design Review Coordination 3.5 4D Project Management / Integration / Visualization --------

  18. II. Overview of 3DL • 3DL Background & Credentials • 3DL Capabilities & Services • 3DL Integration Services • 3DL Cost Advantage ----------

  19. II. Overview of 3DL • 3DL Cost Advantage 4.1 Hit the ground running • Specific Digital Manufacturing Skills: Ready • Specialized Software: Ready • Experienced IT and DM Business Process: Ready • Relationships with other DM Specialists: Ready

  20. II. Overview of 3DL • 3DL Cost Advantage 4.2 Preserve Core Business Integrity • Stay focused on Core Business • Adopt DM as an additional tool to enhance your reputation, not replace it • Migrate to DM internally, one step at a time

  21. II. Overview of 3DL • 3DL Cost Advantage 4.3 Design sustainable operations • Ensure Digital Models are “Downstream Compatible” • Ensure that libraries enable future efficiencies • Ensure that DM data is accessible for Post Sales support and Future business possibilities • Adhere to Drawing and File Standards ** DM is here to enhance your core business, not to distract from it **

  22. 3D - Layouts Agenda • Overview of Digital Manufacturing • Overview of 3DL LLC • Value of Digital Mfg / 3DL for Industrial Facility Engineering Companies

  23. Digital Manufacturing (Slide Borrowed from CV Eng) Digital Models Intelligent, 3D Engineering Collaborate Digitally Design reviews Visual, Accurate, Comprehensive Install DrawingsComplete, accurate, on time Product Equipment/ Process Facility 3DL Provides / Integrates IT infrastructure Connectivity File Management Reuse, Libraries Project Management CAD/CAM/CAE Simulation • Security • Change Control • File Size / format • Standards • Efficient models • Existing Solutions • Task Planning • Visual progress depiction • Cost / Resource impact • Common Digital Models for all Analysis • Enable Simulation modeling • Capable network, computing, software • Collaboration enabled

  24. …migration map (Slide Borrowed from CV Eng) 3DL * Candidate 3D Layouts and Digital Manufacturing partner

  25. 3DL Value: Performance InitiativesTiming / Quality / Throughput / Cost Project Timing • ShorterPlanning Cycles • Fast Deployment • On Time Starts Quality: Study Completely… Implement only Once • Communicate Correct Details • Project is understood • Minimal Change Orders Click for Timing detail Click for Quality detail

  26. 3DL Value: Performance InitiativesTiming / Quality / Throughput / Cost Throughput : Ability to... • Produce Digital Models and Studies • Produce Virtual Builds • Communicate to/from all Stakeholders Cost: • Accurate bids • Controlled project cost, with minimized Capitalinvestment and Operating expense (minimal changes / wait time) Click for Through-put Detail Click for Cost Detail

  27. CV Eng Steps to begin DM 3DL’s suggested SNA Scope of Work • Capture the Existing Facility, Digitally • Laser Scan  Convert: to 3D Layouts • Convert CV Eng 2D Drawings  3D Layouts • Create a re-start “Base Zero” in 3D • Create Re-Start 3D Bid Packs • Run Design Reviews in 3D • Use 4D Timeline in regular Project Reviews • -----------

  28. 3DL Thank You Questions / Comments / Action Items

  29. Questions / Comments / Action Items Thank You

  30. Timing:- Shorter Planning Cycles- Faster deployment- On Time Starts (no surprises, systems validated) • Digital iterations occur in days. Many scenarios are “spun” searching for solutions compliant with all requirements. • All scenarios are developed and validated digitally. Accurate data is provided to stakeholders for: • validation, compliance and buy-off • Live, On-Line design reviews occur “real time” • Sections are NOT cut, 3D provides “Real” views • Verify “As-Builts” before and after.----------- Click Here

  31. Quality: Conformance to RequirementsStudy Completely…Implement only Once • Comprehend all Stakeholder requirements • Reference Drawing Life Cycle  Develop & Validate concept drawings  Enhance same drawings into details  Create installation drawings from same  Integrate 3rd party drawings  Reconcile Drawings with Laser scans • Libraries of reusable (Parametric) Objects • 3D Visualization for all Stakeholders Click here

  32. Throughput:- Produce Digital Models and Studies- Produce Virtual Builds- Communicate to/from all Stakeholders • Create 3D Models faster then 2D Drawings • Produce iterations in fractions of the time • Build complete models without sacrificing thoroughness due to time constraints • Optimize deployment plan • smallest possible staff, inventory and equipment, on hand • avoid unscheduled overtime • de-coupled tasks / project elements • “orchestrated” complex movement and time based events Click Here

  33. Cost: Engineering budget to develop programCapital investment Construction expense • 3D design cost are less then 2D design cost. • Models are reusable and reduces cost of downstream drawings • 3D Visualization enables “Clear” design reviews to avoid errors, omissions and late changes • Enables cost reduction for construction materials and scheduling -----------

  34. Cost: Field Checking Cost Reduction

  35. Cost: Expected Cost reductions • First project will improve re-launch of SNA Start Up: • Enable SNA to better Manage the Plant Construction • Accurate capture of existing plant status • Better understood bid drawings • Reduced Field orders • Improve Time Line Execution (Web Based and 4D) • Highly visible project progress (Web Based) ------------

  36. Cost: Expected Cost reductions • First project will improve re-launch of SNA Start Up: • Enable SNA to better Manage the Plant Construction • Accurate capture of existing plant status • Better understood bid drawings • Reduced Field orders • Improve Time Line Execution (Web Based and 4D) • Highly visible project progress (Web Based) • Downstream projects will save cost on all of the above, plus; • Reuse of special Objects - Benefit from Parametric Libraries • Adherence to Standards - Reduced lead time/cost for repeat work • Created Intellectual Capital - No need for 2D  3D conversion • CV Engineers, 3D capable - Embedded Meta Data in Smart Objects -----------

  37. Manufacturing Simulation -- High Level Value -- • DES Discrete Event Simulation • WCV Work Cell Visualization • CAE Computer Aided Engineering • Process Planning Simulating Process Events • Commissioning Simulating / Validating PLCs • MES Mfg Execution Systems --------

  38. Manufacturing Simulation -- DES & WCV -- • DESDiscrete Event Simulation is the Process of running a series of “Time Based Events” dynamically, as a system • Example: machining centers with different feed rates, conveyors, tools with MCBF and MTTR (Automod) • WCV Work Cell Visualization is the process of running Geometric Shapes Dynamically through their motion paths, on a timeline • Example: Robots / Automated Machinery / Humans moving & manipulating product in a confined space (RobCad / Delmia) ----------

  39. Manufacturing Simulation -- CAE & PP -- • CAE Computer Aided Engineering is a diverse set of Engineering Analysis and Simulation tools • Example: Structural Analysis, Fluid Dynamics, Mold Flow Analysis, Electrical Distribution Simulation, Machining Simulation, etc. • Process PlanningProcess Simulation, incorporating Process Steps, Resources Required, Motion Analysis, Physical Space required, Model Mix, Volumes, Tool Changes, Maintenance, etc. • Example: Pro-Planner, Process Simulate (TC) -----------

  40. Manufacturing Simulation -- Commissioning & MES -- • Commissioning Simulating and Validating Control Logic for Plant Systems in a Dev. Environment • Example: Ladder Logic driven from desk computers triggering Allen Bradley PLCs, based on a series of sensors and switches as designed for plant installation • MES Manufacturing Execution Systems tie the Plant Data Acquisition systems to Production Planning Systems, to Process Planning Software. • Example: Using “real time plant data” to continuously update software and drive efficient performance ----------

  41. WCV : Work Cell Visualization Body Marriage • 3D Geometry • Defined Motion • Detect Collision • Visualization Click here

  42. DES : Discrete Event Simulation Door Line Engine Delivery • Time based events, with predecessors • Statistical events (Repairs, traffic, etc) • Configuration Analysis; # of Carriers, people, tools, • - Decoupling Tasks • Simple 3D Objects for Visualization • Scripted Motion for Visualization • No Collision Detection Click here

  43. 3-D Layouts: Digital Drawings -- High Level Value -- • 3D Layouts Enable integration of multiple math models into one digital environment • Geography - Foundations - Building • Equipment - Transportation - Product, etc • 3D Fly-Through Enables stakeholders clear project understanding: visualize the plan • Digital Drawings Continuous Improvement of the same drawings; Concept  Approved Plans  Installation

  44. 3-D Layouts: Digital Drawings -- Digital Accuracy-- • 3D Laser Scanning Capturing the environment in 3D, using Laser scanning: import into Autocad • Design Reviews Regularly run 3D Layout reviews. Stream Collaboration reviews, globally • Reconcile “As Built” to Drawings. Enable Management decisions about:changing physical vs drawings ------------

  45. 3-D Layouts: Digital Drawings -- Efficiencies -- • 3D “Real” objects Drawing errors cannot occur in 3D. Sections are never cut, they are “Views” of existing data. 3D drawings can “look” like 2D plan views, if required • Parametric libraries Intelligent libraries are built; Supplier items, Building Code requirements, equipment, etc. • Object Libraries become Intellectual Capital for Engineering Companies and their Customers • Objects are correct, compliant and actually exist

  46. 3-D Layouts: Digital Drawings -- Project Monitoring -- • Project Monitoring Project progress and deliverables can be clearly agreed and visualized by all stake holders • 4D Project Plan 3D Interactive Layout • Install Documents Thorough communication to all stakeholders. Project Phases and detailed “Skill Trade” drawings in 3D & 2D • Assess Changes Accurately assess changes to the plan ------------

  47. 3-D Layouts: Digital Drawings -- New Options-- • Project Documentation Evidence of completion and contractual documents (recreation of events / situations / safety) • Training Virtual Flythrough and visualization, during and after construction • Rendering Creation of “Studio” quality images, video clips and illustrated “Issues” • New Business Opportunities High Quality Marketing materials for Competitive Selling ------------

  48. 3D Layout: Truck Plant • 3D Digital Plant, Product and Tools • Static Drawings, viewer Fly-Thru • Light Weight Models: Some Parametric Objects from Library some Simple Blocks

  49. 3D Layouts:

  50. TraditionalBlueprint 3D Solid Cad Model Tool Design Technology Progression