A parasolid 3D environment is a powerful tool for the visualization and planning of workflow and equipment placement in industrial facilities.
The images below are taken from a study conducted for a confidential client in the Middle East. I both acquired the client and directed the teams which undertook the on-site analysis and the factory re-design process. The on-site team live conducted a month-long review of the client's entire operation, from staffing, to workflow, purchasing, design and production management. Daily reports and frequent adjustment of the work plan rapidly revealed the key issues and focused our efforts on problem solving.
The process started with the creation of a 3D model of the existing building, followed by documentation of the existing layout and progressed to trial layouts, discussion and revision, resulting in recommendations regarding new equipment and a new layout.
The buillding model was then revised to show the proposed equipment configuration and workflow, together with new work support fixtures and high-efficiency interior and exterior cranage and transfers.
The next step in the process is to detail the required shop-fabricated components to a manufacturing / fabrication level.
Images used courtesy of Feature Walters under license
Exterior view of building model
The restricted site required all inbound material and outbound products to pass through one end of the rectangular lot.
An ideal structural steel plant has a linear workflow, whereas the 4-bay layout and single-end access of the client's existing plant required a folded workflow. This compelled the project team to focus on the reduction of material handling steps using lateral transfers and dedicted processing bays
The resulting factory layout features a dense array of material handling devices, tool positioners and adjustable work supports trestles which create a work environement that maximizes throughput and is simultaneously safe and efficient.
A combined cutting / drilling line located adjacent to the inbound material storage bay reduces interior space requirements to a minimum while maximizing the productivity of the handling crane.
Specialized workholding fixtures reduce fitting time for repetetive assemblies
Work support trestles maximize accuracy and increase productivity
