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Redefining the Digital Factory
Integrating the Factory Lifecycle with PLM
Lutz Bettels, Vice President Manufacturing & Facilities, Bentley Systems Inc.
Bentley Systems Inc. – a global software leader
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Bentley Solutions for the World‘s Infrastructure …
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Bentley Solutions for the Digital Factory
• Site Infrastructure and Master
Planning
Operate
Build
– Geospatial Mapping
– Surveying Data Display
– Utility Planning and Documentation
– Site Design and Civil Engineering
– Site Master Planning
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Design
Bentley Solutions for the Digital Factory
• Space Programming and Block
Layout
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Import space program and schedules from Excel
Create block layouts in 2D or 3D
Run graphical space reports (thematic maps)
Query data model and analyze space layout
Create professional space schedules
Integrate reporting tools
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Bentley Solutions for the Digital Factory
• Factory Design (BIM) incl. Point
Cloud Data
– Architectural Design
• Any building types (factories, warehouses, offices …)
– Structural Design and Analysis
• Building structures, platforms, conveyors
– Building Mechanical Design
• HVAC, plumbing, media
– Building Electrical Design
• Raceways, cabeling, lighting, network, security
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Bentley Solutions for the Digital Factory
• JT Data Exchange
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JT import, export and referencing
3D clipping capabilities to export partial models
Support of levels and structured data export
Level of detail support
File size and performance optimizations
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Bentley Solutions for the Digital Factory
• Teamcenter Integration
– Automaticaly generate JT renditions
of factory model in continuous quality
– Distribute partial factory JT models
and PLMXML to process engineering
– Receive process layouts through JT
and PLMXML in factory design and
layout
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Bentley Solutions for the Digital Factory
• Point Clouds for Layout and Design
Validation
– Leverage point cloud directly for early phase
layout design
– Evaluate early layout designs without need for 3D
modeling
– Validate 3D layouts in context of or against point
clouds
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Bentley Solutions for the Digital Factory
Courtesy of Volvo
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Bentley Solutions for the Digital Factory
• Factory DMU
– Reference process layout in digital factory model
to create mockup model
– Inspect complete digital factory model
– Perform clash detections and identify
interferences
– Create markups and distribute in factory design,
layout and process engineering
– Manage versions and revisions
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Bentley Solutions for the Digital Factory
• Construction Management and
Progress Monitoring
– Define work packages and analyze construction
sequenzing
– Distribute work packages to contractors and
capture construction status with mobile devices
– Monitor construction progress through status
visualization in digital factory model
– Compare as-built scanned vs. as-designed 3D
model throughout construction to avoid
subsequent errors and omisions
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Bentley Solutions for the Digital Factory
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Bentley Solutions for the Digital Factory
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Bentley Solutions for the Digital Factory
• Asset Lifecycle Information and Performance Management
Master Asset
Register
Change
Events
Asset
People
Asset
Organizations
Location
Documents
Drawings
Transmittals
Federated Factory World
Requirements
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Impact analysis
Bentley Solutions for the Digital Factory
• Bentley completes the Digital Factory
with solutions for:
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Site infrastructure and master planning
Space programming and block layout
Factory design (BIM) and layout
As-built point cloud data utilization, editing and
management
Process engineering integration through JT
Information mobility with Teamcenter
Factory DMU
Construction Management
Asset lifecycle and performance management
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Redefining the Digital Factory
Seamless Integration of Factory Infrastructure Design and Manufacturing Engineering
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Digital Factory Building Blocks for Discrete Manufacturing
Factory
Process
Product
Process
Factory
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Product
Process and Factory Planning Fields
Building
Floor
Line
Cell
Operation
Single Process
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Process Planning
Product Engineering Software
Manufacturing Engineering Software (Process Design, Simualte and Program)
Orders
Purchasing
CAD
Plant BOM
CAE
Mass BOM
BOP
Prototype
Testing
ERP
Production
Planning
Serial
Planning
Software
Siemens PLM Software Integrated Product/Production Definition
Process Planning Environment
• Product Design, Analysis and Simulation
• Tool and Equipment Design
• Process and Resource Planning
• Manufacturing Sequencing and Workflows
• Process Analysis and Simulation
• BOM and SAP Integration
• Manufacturing Cell and Line Layout
• Production Simulation
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Plant Floor
Devices
Quality
Factory Planning
Asset Information
Management
Engineering Work-In-Progress Management
Pointtools
Master Planning
Bentley Map
Factory Model
AECOSim
Building Designer
Factory Layout
Facilities Space
Planner
Site Infrastructure
Bentley sisnet
Detailed Factory
Layout & Design
Factory As
Built Scan
Factory
DMU
Building, HVAC, Electrical, Media
AECOSim Building Designer
Conveyor Systems
MicroStation
Logistics
Facilities Space Planner
Bentley
Navigator
Clash
Resolution
AECOSim
Building Designer
Bentley Facilities
eB
Asset Performance
Management
Ivara
Operate
Factory Infrastructure Design & Build
Factory Planning Environment
• Building Design
• HVAC and Electrical
• Structural Analysis.
• Integration to Production Systems
• Conveyor System Layout and Design
• Visualization and Interference Detection
• Factory Layout (overall, line, cell)
• Factory Mockup
• Energy Simulation
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Factory
As Built
Documentation
Bentley Siemens Positioning
Building
Floor
Line
Cell
Operation
Single Process
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Product Lifecycle Complements Factory Lifecycle
Product Engineering Software
Manufacturing Engineering Software (Process Design, Simualte and Program)
Orders
Purchasing
Plant BOM
Mass BOM
Prototype
CAD
CAE
BOP
Software
Testing
ERP
Production
Planning
Serial
Planning
Plant Floor
Devices
Quality
Siemens PLM Software Integrated Product/Production Definition
JT
JT
JT
Asset Information
Management
Engineering Work-In-Progress Management
Factory Model
Pointtools
Building Designer
Master Planning
Bentley Map
AECOSim
Factory Layout
Facilities Space
Planner
Site Infrastructure
Bentley sisnet
Detailed Factory
Layout & Design
Factory As
Built Scan
Factory Infrastructure Design & Build
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Building, HVAC, Electrical, Media
AECOSim Building Designer
Conveyor Systems
MicroStation
Logistics
Facilities Space Planner
Factory
DMU
Bentley
Navigator
Clash
Resolution
Factory
As Built
Documentation
AECOSim
Building
Designer
Bentley Facilities
eB
Asset Performance
Management
Ivara
Operate
Integrated manufacturing process planning and factory layout design
Detailed
Production
Planning
DEVELOP
BUILD
SUPPORT
3
Robot line
engineering
Production
Planning
Factory
Planning
OEM
OEM
Line Builder
PLAN
2
• Planning a new body-in-white line
in an existing facility (brown field
project)
5
Process planning
in factory context
Update planning
and validation
4
1
3D factory and
point cloud model
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Detailed factory
design and
analysis
• Integrated workflow scenario for
process planning and factory
layout
• Challenging scenario due to data
amount and complexity
Line Builder
Detailed
Production
Planning
OEM
Production
Planning
Integrated Workflow for Process and Factory Design
based on JT Visualization Standard Format
Robot Line Engineering Line Layout
Concept Process & Layout
3
Detailed Process & Layout
Process Planning in
Factory Context
Update Planning and
Validation
2
5
Factory
Planning
OEM
Factory Layout
Model
Line Layout &
Clearance Zones
Detailed Factory
Layout Model
3D Factory and Point Cloud
Model
Detailed Factory Design and
Analysis
1
4
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Integrated manufacturing process planning and factory layout design
PLAN
DEVELOP
BUILD
SUPPORT
• Planning a new body-in-white line
in an existing facility (brown field
project)
• Integrated workflow scenario for
process planning and factory
layout
• Challenging scenario due to data
amount and complexity
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Factory As-Built Model
Advantages
Benefits
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Collect existing 3D designs and 2D layouts in one
environment
 Accurate and up to date 3D as built information model
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Perform and incorporate 3D laser scans in factory model
 Aggregate information to be passed on to Process Design
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Prepare 2D space program in 3D factory context
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Leverage point clouds to make early layout decisions
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Build 3D factory information model on top of point cloud
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 High quality initial layout related to 3D factory model
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Process Planning Concept
Advantages
Benefits
 Process planning in building context
 Synchronize process and factory development stages
faster and with greater collaboration
 Start concept process planning with current plant layout
 Sharing 3D-footprints between manufacturing engineering
and facilities engineering through JT
 Process (change) validation in as-built point cloud scans
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 Align virtual production model and physical production
equipment
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Detailed Planning and Validation by Supplier
Advantage
Benefits
 Detailed cells and line planning by line builder
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Synchronize process engineering development stages
faster between OEM and supplier
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Analyze the impact of changes quickly and continuously
improve with iterative validation
 Robot programming & validation
 Robots smart placement for best location of robot
 Resulting in consolidated line design
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Volvo Cars – Case Study with Point Clouds and Tecnomatix
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Detailed Factory Layout
Advantages
Benefits
 Complete factory layout and design (HVAC, Electrical,
Media) with process engineering context
 Reduce factory design iterations by incorporating relevant
process design information in factory layout process
 Update laser scans into 3D information model
 Avoid errors and omissions because of factory mockup
 Perform Factory DMU between product, process and
factory
 Decrease effort for creating building performance
simulations
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Update Process Planning
Advantage
Benefits
 Update process planning after collision was found in
factory layout
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React quickly to changes by creating process plans and
factory design more efficiently
 Process change in the context of the real factory layout
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Connecting distributed people with the right information in
the right context on time
 Send collision free line design back to factory layout design
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For more information:
1-800-BENTLEY (1-800-236-8539)
www.bentley.com
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