Digital factory planning

Optimizing value creation processes with digital factory planning

The factory planning process comprises individual steps, from basic evaluation and concept planning through to implementation and ramp-up support. The aim is to create structures and processes in order to optimize value creation processes. In the following article, I will introduce you to the topic of digital factory planning and show you the differences to classic factory planning. I will also explain the benefits of the planning phase and how the use of digital methods can make the factory planning process easier for the factory planner.

The article includes the following sections:

1. The concept of digital factory planning: What describes digital factory planning?
2. Optimization potential in the planning process: What potential does digital factory planning offer compared to traditional factory planning?
3. 3D visualization and the use of VR: software solutions for visualization and interfaces to virtual reality
4. BIM as a data basis for digital factory planning: What does Building Information Modeling describe and what possible applications does it offer in digital factory planning?

The concept of digital factory planning

The data available at the start of the planning project forms the basis of every planning project. However, the desire of every planner for complete, structured data is rarely fulfilled in reality. This is because the information required for factory planning is often incomplete or insufficiently documented. However, technical progress is making it possible to digitize more and more knowledge. As a result, companies can increasingly exploit the potential of digital factory planning. To discuss this in detail, I will first provide a comprehensive overview of digital factory planning. I will then explain how you can create the best possible data basis.

Tools and methods of digital factory planning

There are various definitions and approaches to the term digital factory planning. Digital factory planning usually functions as a series of digital tools, methods and interfaces. Companies can use these depending on the situation and the type and complexity of the factory planning task. The fields of application range from the planning of factory and material flows to the planning of equipment, production and logistics processes through to the planning of detailed manufacturing processes. Tools are designed for specific process steps, while methods are used throughout the entire factory planning process. The use of virtual reality and augmented reality acts as a user interface. A variety of factors can trigger a factory planning project and the use of digital tools and methods. Examples include new products and markets, changes in legal requirements, location adjustments, restructuring of process or material flows as well as new technologies and procedures.

How digital factory planning can optimize the planning process

The possibilities for the use of digital factory planning are diverse and can be described using both quantitative and qualitative criteria. Methods and tools can be used at an early stage, especially in the initial planning phases such as rough or layout planning, to increase quality, reduce costs and minimize factory planning time. The following potentials can be identified:

Compared to traditional factory planning, the planning methodology and communication between the parties involved has changed enormously. By using both software and hardware, complete factory layouts and material flow systems can be generated with the help of simulations and visualizations, which can be used in a results-oriented manner within both greenfield and brownfield planning.

Data-based decision-making

Overall, the use of the correct IT tools protects the planner against misjudgements and, in combination with simulation results, offers a broader horizon for carrying out their tasks. In addition, we can quickly and clearly visualize the current planning status across all hierarchical levels, whether at store floor, planning or management level, so that you have a concrete picture in front of you at all times. On this basis, different solution concepts and scenarios can be developed and discussed together with all stakeholders so that a result- and goal-oriented planning project can be carried out. This is why we at Rothbaum consider it necessary to record and evaluate all the alternatives offered by digital factory planning and to use them in a targeted manner according to the scope and complexity of the project.

3D visualization and the use of virtual reality

Efficient layout and detailed planning requires tools to design and visualize the processes in the production, assembly and logistics areas in detail. A wide range of methods and tools are now available to enable digital factory planning. In the following, I will give you a brief insight into selected tools for 3D visualization and the interface to virtual reality.

Selected software solutions

In the past, many tools for factory planning have already been developed by renowned companies to ensure entry into 3D factory planning. Some of these include complex simulation tasks, while others focus on the visualization of layouts. The following software solutions for the visualization and representation of factory layouts deserve special mention here:

1. Siemens Plant Simulation: A comprehensive software used for modeling, simulation and animation of production and logistics systems as well as business processes.
2. Visual Components: This software impresses with its user-friendly, powerful and optimized visual animation of factory planning objects. The interface to VR is particularly impressive.
3. visTable – From value stream to 3D factory: This software can be used to design comprehensive layout plans and material flow systems. The wide range of possible applications in relation to the planning and visualization of complex warehouse, logistics and factory concepts enable planning with different levels of detail. The simulation and evaluation of scenarios enables fast and reliable decision-making throughout the entire project phase.

Data modeling in 3 dimensions

In order to be able to use the software solutions mentioned, a high level of data quality is absolutely essential for a planning project. However, the data basis for a complete visualization of factory layouts is usually not available. Often 2D layouts are available, which have to be concretized at the beginning of the planning process. The aim of any digital factory planning should be to move from a 2D layout to a 3D layout in order to be able to generate one or more dynamic models at the end. Based on these models, simulations for material flow or ergonomic considerations can be generated. The advantage of simulations is obvious: logistical relationships can be presented quickly and clearly. Even a simple graphical representation can help to better evaluate logistics concepts. The graphical representation of workplaces makes it easy to carry out ergonomic analyses. If you would like to find out more about sustainable simulations, I recommend this article by my colleague on the use of the Digital Twin.

Augmented reality in factory planning

In order to fully exploit the potential of digital factory planning, it makes sense to use virtual reality or augmented reality. The aim is to further network the interface between people and technology in order to make even better use of the potential. With the help of adapted software solutions, a realistic visualization of the current planning status is guaranteed in real time. Both the planner and the customer can take interactive and virtual tours of production or view newly planned machines in real existing hall structures. Overall, the use of VR significantly increases the degree of immersion of the planning model in contrast to two- or three-dimensional layouts. This creates new possibilities for the design and planning of factory layouts, conveyor systems, storage systems and individual workstations.

Building Information Modeling as a data basis (BIM)

The question that arises at the beginning of every planning phase for 3D visualization is the availability of information or data about the underlying planning object. In order to generate a sufficient data basis, high-tech methods such as laser scanning or photogrammetry can be used. Another concept that enables a detailed planning process is Building Information Modeling (BIM). But what is BIM? Here is a brief summary:

The traditional way of exchanging information during the planning phase is to communicate in paper form or via a wide variety of software solutions. This leaves room for a multitude of possible interpretations and misunderstandings, which usually result in high costs. The result is that time frames and budgets are exceeded. To counteract these consequences and ensure efficient and error-free work, it makes sense to use a single format that can be accessed by all parties involved.

This is exactly what the BIM method represents digitally. A central model is created, which is fed by the respective specialist planners with the help of separate models. These models relate, for example, to the architecture, statics or technical building equipment of a project. The aim is for the central model to ultimately store all relevant information relating to all of the building’s component properties.

BIM in digital factory planning

Digital factory planning can utilize these advantages and expand them to include the planning fields of production systems, operating resources and IT. This allows a holistic process to be represented. Some interfaces to CAD systems already exist for digitizing information with the help of BIM. However, the current technology shows some potential, as this CAD interface reaches its limits with more complex planning. The aim of the BIM methodology is to collect, provide and use information in order to visualize factory layouts in three dimensions, for example. The current development of an interface between BIM and immersive visualization systems is essential for this. It should also be possible to feed changes made in the virtual world back into the BIM software so that the results of meetings can be incorporated directly into the planning.

Summary

Digital factory planning offers a lot of potential compared to the classic factory planning process. Innovative tools, simulations and interfaces can be used to generate flexible and adaptable factory systems. The aim is to generate networked models in the context of digital factory planning and to use simulations to check the feasibility of an investment. In the age of digitalization, the use of software and hardware for layout planning and material flow analysis is indispensable. A reliable data basis in combination with the experience of planners and employees in the company makes it possible to generate well-founded results.