part2

In the ideal world, every factory would have accurate, fully dimensioned, 2D/3D drawings of every part of the facility so new plant modifications can be easily designed. While this would be in place for new plants, in reality the first step in plant remodeling to meet demands for new products is often a time-consuming measurement and drawing process.

For complex plants, this takes too long and it can be difficult to attain high levels of accuracy. This lack of visibility often means that initial discussions of new layouts at a senior level are delayed or made worse by relying on inaccurate layouts.

HOW DOES 3D SCANNING WORK?

The most common scanners for this purpose are tripod based with a rotating scanner and camera, with the camera there to color the scan points. The laser scanner uses phase shift to measure the distance between points from the scanner location. At each position, the scanner captures hundreds of thousands of measurement points per second in a full 360 degree data capture, creating a complete sphere pattern of dot positions. As equipment within the room obscures the scanning process, multiple scans from different positions are required to obtain information from all sides of the area’s contents.

Once multiple scans for a single area are complete, post-processing stitches together millions of data elements into a “point cloud.” The process is then repeated for other factory areas with post-processing joining individual point clouds together to create a “project point cloud” of the entire site.

THE OUTCOME

The results of the process permits a 3D “walk through” of the “as installed” plant to a measured accuracy of up to 2mm, with the ability to dimension and add annotations to any 3D element.

That means plant remodeling is based on accurate data making the design process much quicker. It also means that reverse engineering of assets and components is possible. While 3D computer-aided design (CAD) users are likely to have powerful workstations to access files, standard users are supported by a secure web application that allows unlimited views within the organization from standard desktop personal computers.

The accuracy is so good that at a recent exhibition, many visitors thought the 3D scanned images were videos until they were shown how to “walk-through” and measure elements.

3D scan to CAD is 12 times faster than manual measurement.

TYPICAL APPLICATIONS

Although 3D scanning for video games and the entertainment industry may be exotic, there are many uses that could be considered for factory use.

Import to 3D CAD: This is probably the most obvious requirement for project engineering and maintenance teams. The 3D scan to CAD process is 12 times faster compared to manual measurement with much higher accuracy rates. The point clouds are imported into software that sections the point cloud and uses the points to create a geometric configuration, a bit like tracing in 3D. The days of tape measure, paper and camera to create CAD layouts must surely be coming to an end. The three-step process of 3D scan – point cloud – to 3D CAD means that by step two, the 3D walkthrough and ability to dimension and annotate is available within a few hours. That means benefits are gained while work continues on the final step, the import to 3D CAD for further design work. Although import to CAD is important, it is estimated that as much as 60 percent of the benefit for the factory team could be gained once the point cloud has been created in step two.

Supplier Review: Want a potential supplier to quote for plant modifications, but don’t want him or her to see the full site? Don’t have time for the supplier to arrange a site visit? Give the supplier secure web access to a restricted part of the plant from his or her own location. The ability to walk-through and dimension allows both parties to view simultaneously and compare ideas and thoughts online. This allows more potential suppliers to be involved and reduces project quotation time.

Reverse Engineering: Have failed asset components from obsolete equipment, or missing CAD files from an old project? Use 3D scanning to quickly digitize a part and create a fully surfaced CAD model that can be then used to reproduce a local copy. There is no effective limit in terms of size, with larger and more complicated items just needing more scans.

Plant Reviews: The regional management team wants to quickly review plant layouts. Of course, a Gemba (or Genba) visit to the manufacturing floor is better, but for an initial check or quick safety review, a 3D walk-through will be quicker and much more realistic. The ability to dimension also means that initial assessments can be made to see if the new kit could possibly fit in that position.

Asset Register: Creating an asset register from scratch takes a long time and it’s not unusual for the process to take months. While a 3D scan won’t identify the plant nameplates or serial numbers, it’s a great start and will speed up the equipment identification process. Database links can be made in both directions with the 3D scan point cloud able to load an asset register and the asset register, in turn, able to load the 3D scan point. The is no reason why the process cannot be part of maintenance checks with the inspection content linked to, and taking the engineering to, a precise location in the 3D scan point cloud for a physical review.

Incident Investigation: One final application you may hope not to use is forensic crash investigation, which allows data to be recorded for office-based analysis and supports vehicle deformation comparisons against standard measurements. Could those techniques be used for industrial incidents? Almost certainly.

Being able to walk-through an accurate 3D layout increases plant visibility significantly. It’s as close as you can get to actually being there in the room. 3D scanning is here to stay with more uses being identified daily. Try it out and you’ll wonder how you managed without it.

Keep reading...Show less

Upcoming Events

August 9 - August 11 2022

MaximoWorld 2022

View all Events
banner
80% of Reliabilityweb.com newsletter subscribers report finding something used to improve their jobs on a regular basis.
Subscribers get exclusive content. Just released...MRO Best Practices Special Report - a $399 value!
DOWNLOAD NOW
“Steel-ing” Reliability in Alabama

A joint venture between two of the world’s largest steel companies inspired innovative approaches to maintenance reliability that incorporate the tools, technology and techniques of today. This article takes you on their journey.

Three Things You Need to Know About Capital Project Prioritization

“Why do you think these two projects rank so much higher in this method than the first method?” the facilitator asked the director of reliability.

What Is Industrial Maintenance as a Service?

Industrial maintenance as a service (#imaas) transfers the digital and/or manual management of maintenance and industrial operations from machine users to machine manufacturers (OEMs), while improving it considerably.

Three Things You Need to Know About Criticality Analysis

When it comes to criticality analysis, there are three key factors must be emphasized.

Turning the Oil Tanker

This article highlights the hidden trap of performance management systems.

Optimizing Value From Physical Assets

There are ever-increasing opportunities to create new and sustainable value in asset-intensive organizations through enhanced use of technology.

Conducting Asset Criticality Assessment for Better Maintenance Strategy and Techniques

Conducting an asset criticality assessment (ACA) is the first step in maintaining the assets properly. This article addresses the best maintenance strategy for assets by using ACA techniques.

Harmonizing PMs

Maintenance reliability is, of course, an essential part of any successful business that wants to remain successful. It includes the three PMs: predictive, preventive and proactive maintenance.

How an Edge IoT Platform Increases Efficiency, Availability and Productivity

Within four years, more than 30 per cent of businesses and organizations will include edge computing in their cloud deployments to address bandwidth bottlenecks, reduce latency, and process data for decision support in real-time.

MaximoWorld 2022

The world's largest conference for IBM Maximo users, IBM Executives, IBM Maximo Partners and Services with Uptime Elements Reliability Framework and Asset Management System is being held Aug 8-11, 2022