Customer Challenge
Cell Layout Optimization – Scan Data Points
- Oil & Gas component manufacturer wanted to optimize cell layout to improve throughput & maximize profitability.
- Present cell of Down hole Drill tools had Zig-Zag work flow with turning, milling and drilling operations with unwanted material movement and bottlenecks.
- Customer doesn’t have cell layout drawings or 3D models.
- They want to create 3D virtual factory layout to simulate and validate through digital twin.
Scope
To develop 3D model of existing cell layout by utilizing scanned digital point data and virtually simulate to validate the manufacturing efficiency and improve throughput by eliminating bottlenecks
Solution
- Analyse cell layout, part details and routings
- Scan cell area and generate point cloud data
- Draw value stream map and optimize movements
- Conceptualize Factory Layout & Establish work content
- Build 3D layout and virtual commissioning
- Virtual cell simulation for analysing ergonomics and movements to ensure productivity, safety and quality
- Design & Process Failure Mode and Effects Analysis
- Process flow diagram
- Cell Layout assembly and detail drawing
Features
- Quest Global with its expert capabilities, reviewed industrial requirements, part families & factory area to scan, design & develop new feasible concepts & virtually simulate process design solutions through failure mode effect analysis
- Deliverables: Scanned point data, 3D Factory models, detailed & Assembly Manufacturing Drawings, Updated routers , Line of Balance & Precedence charts
- Tools Used : PLM Teamcentre, Siemens Tecnomatix, Manufacturing Planning & Nx.
Benefits
- Scanning technology saved 30% of man-hours to build 3D model of factory
- Generated point cloud data of factory with an accuracy of 2mm
- Optimize factory space by 23% to accommodate new machines
- Increase throughput by 30% by reducing non value added time
- Design, Validate and commission manufacturing lines on a single PLM platform