“Digital and Simulated Glass Plant Design”
Transcript of “Digital and Simulated Glass Plant Design”
CONTAINER GLASS
GLASS WOOL
E-GLASS
TABLEWARE
SPECIAL GLASS APPLICATION
“Digital and Simulated
Glass Plant Design”
cm.project.ing GmbH is your independent consultant in the glass industry that supports you optimal and holistically in project management
as well as in engineering of major industrial projects.
Innovative Glass Plant Engineering and Project Management
Additionally the cm.project.ing is member of
several glass organizations to be up to date
for new technologies and to increase the
know-how of the company.
CMP - INTRODUCTION
01/23
RISK
Low Grade of
Automation
High
Investment
Costs
Profitability only by
High Operation Efficiency
Engineering Phase
HOLISTIC PLANT LAYOUTING
02/23
costs for
• raw materials
• energy
• labor
availabilities
• energy
• local supply
Concept Phase Definition of Basic Parameters
Fixed Tech. Data Sheet Layout
CAPEX Time Schedule
OPEX
technical data sheet
plant configuration
production planning
• IS Machines
• followers
• packaging
2a
prelim. eng. spec. core / utilities
prelim. civil + architect. spec.
plant organization
balances
Evaluation of Results
Optimal plant layout
High flexibility
Cost optimized
High quality
Optimal process efficiency
1
2b
3
4a
5
environment
norms + standards
geological data
Budget Time
4b
4c
tonnage
portfolio
7
6
Quality
Logistic Simulation
3D Mapping
Tool
CFD Simulation
Production Plan
Calculation
CMP DOCC Tool
CMP VR Tool
Logistic
Simulation
3D Model
3D Mapping
Tool
CMP VR Tool
CFD Simulation
OPTIMIZED PLANT
LAYOUT
Input
Processing, Simulation,
Validation
CUSTOMER NEEDS
PRODUCTION STRATEGY
BOUNDARY CONDITIONS
HOLISTIC 3D MODEL
CMP DOCC TOOL
LOGISTIC SIMULATION
ARCHITECTURE
CFD VISUALIZATION
CMP VIRTUAL REALITY
INVEST COSTS
OPERATING COSTS
PURCHASE & CONTRACT STRATEGY
FLEXIBILITY
PROCESS SAFETY
MAINTENANCE
IN- & OUTBOUND LOGISTIC
AREA USE
ENVIRONMENT
FUTURE EXPANSION
CONSUMPTION
Engineering Experience
QUALITY
CRITERIAS
ANALYSIS, PROCESSING
& SIMULATION INPUT
PROJECT TIMELINE
Benchmarking
PROCESS EFFICIENCY
07/23
Invest CostsOperational
Costs
FutureExpansion
Process Safety
Flexibility
Maintenance
In- & OutboundLogistic
Area Use
Environment
ProcessEfficiency
Quality
Innovation
Process
Simulation
3D
Model
Interconncetivity
Interconnectivity for the best possible solution
3D
Mapping
VR
CFD
Analysis
Logistic
Simulation
DOCC Tool
(Prod. Plan)
Virtual
Commissioning
Automatization
• Use of synergetic effects and combination of
systems to maximize the planning process
output.
Innovative modern plant design
22/23
HOLISTIC PLANT LAYOUTING
Low
Capex Low
Opex
High Flexibility
High
Efficiency
High Product
Quality
Regulations
The determination and focus of
the factory have to be clear
03/23
Invest Costs
Operational Costs
Future Expansion
Process Safety
Flexibility
Maintenance
In- & Outbound Logistic
Area Use
Environment
Process Efficiency
Quality
Innovation
HOLISTIC PLANT LAYOUTING CRITERIAS OF PLANT LAYOUTING
WE STAND WITH OUR
CUSTOMER FROM THE
ORIGINAL IDEA TO THE
START UP OF THE GLASS
PLANT
Plant design is the combination of
different aspects
06/23
Invest Costs
Operational Costs
Future Expansion
Process Safety
Flexibility
Maintenance
In- & Outbound Logistic
Area Use
Environment
Process Efficiency
Quality
Innovation
HOLISTIC PLANT LAYOUTING OPTIMIZED PLANT LAYOUT
CURRENT PLANT STATUS
OPTIMIZED CONCEPT
• Increase of product quality - CFD air flow simulation
• Huge increase of process efficiency - CFD visualization
- Technology comparison
- Logistic simulation
• Increase of flexibility - Intelligent storage solutions
- Product portfolio extension
• Increase of possibilities of future expansion - Intelligent use of space
- Synergetic concepts in utility systems
• Hugh increase in maintenance efficiency
- New workshop concepts
- Walkway analysis
• Increase in In- & Outbound logistic - Dynamic logistic concept simulation
• Less operational costs - Reduction of energy consumption
- Avoidance of down times
• Hugh Increase in innovation - Higher degree of automation
- Avoidance of down times
+15
+25
+20 +25
+10
+20
+15
+5
+15
+25
+25
+20
+15
+20
+10
09/23
-5
+45
+45
HOLISTIC PLANT LAYOUTING
Not enough loading ramps for
trucks
Workshops far away from the
production building
Additional compressor building
Cooling towers too close to
production building Compressors in the basement -
> closer to compressed air
consumers
Crossing in- and outbound
traffic
Optimized loading area for
trucks
No crossing in- and outbound
traffic
Workshops close to machines
Higher efficiency of cooling
towers
Optimized glass plant layout Ordinary glass plant layout
08/23
Step 1: Production planning
Analysis of production demands / targets per line
Analysis of product portfolio
Development of optimal machine configuration
Visualization of plant utilization grade (min, max,
average)
Calculation of expected plant output (sellable
production)
Production target parameters create the framework
for all further planning steps 10/23
Step 2: Operational cost calculation
Simulation of entire production year
Development of labor structure
Detailed calculation of operational costs (labor, raw
material, energy, consumables, maintenance, etc.)
CMP PRODUCTION PLANNING TOOL
CMP DOCC TOOL
LOGISTIC SIMULATION
Planning of internal logistic:
• Simulation and analysis of walkways
• Maintenance simulation
• Downtime detection
• Optimization of production process
• Products and raw materials logistic
• Combination of tasks
0
1
2
3
4
5
6
7
8
Maintenance Shift changes Product changes
wal
kway
/ w
ork
er [
km]
Walkway analysis
Unoptimized Optimized layout Optimized layout + workflow
A simulated and optimized internal logistic
reduces unnecessary distances for routine tasks.
= Faster job changes
= Faster maintenance
= Higher staff crew efficiency.
“Working instead of walking“
SDZ GmbH SDZ GmbH
Total time saved / worker:
2,8 km = 33 min
0,6 km = 7 min
2,1 km = 25 min
- 2,8 km
- 0,6 km
- 2,1 km
11/23
LOGISTIC SIMULATION
Planning of storage capacities:
• Dimensioning of storage areas and buffer
• Simulation of internal product logistic
• Evaluation of different layout concepts
• Increase of warehouse turnover
An optimized internal storage logistic reduces the required
storage capacity and decreases costs!
Higher warehouse turnover = Decrease of storage time = Decrease of storage costs =
Reduction of committed capital
SDZ GmbH
SDZ GmbH SDZ GmbH
12/23
LOGISTIC SIMULATION
Simulation of internal and external plant traffic:
• Optimization of in- and outbound logistic
• Dimensioning of waiting areas
• Faster processing of deliveries
• Simulation of fluctuating arrivals
• Evaluation of future scenarios
• Reduction of impairment for the local population
An optimized internal plant traffic reduces unnecessary waiting
time, traffic jams und storage capacities!
Optimal integration of the plant location into the local
infrastructure without negative effects on the local infrastructure!
SDZ GmbH SDZ GmbH
SDZ GmbH
Waiting area Analysis
13/23
SD
Z G
mb
H
CFD VISUALIZATION
To see is to understand
• Visualization and analysis of air flows inside production
buildings
• Heat emission calculation
• Evaluation of different building concepts in early stage
Detailed analyses of air flows in an early stage can avoid
negative influences on the production process.
14/23
CFD VISUALIZATION
An equipment or opening at the wrong position
can cause unintentional air flows that effect the
production process in a negative way.
• Warm or cold air streams
• Air residence time
• Heat transfer
• Insufficient air supply for equipment and processes
• Air quality
• Smoke spreading
15/23
3D AERIAL SCANNING
• Fully automated aerial 3D scanning
• GPS coordinated movement of quadcopter
• Creation of high detailed 3D model of the landscapes and buildings
• Visual analysis of height differences of the landscape
• Analysis and calculation of volumes for civil works
• Early estimation of earth movement demand
16/23
Holistic 3D Model • Holistic 3D model of glass plant vs. construction site at early stage
17/23
Holistic 3D Model • Holistic 3D model of glass plant vs. construction site at early stage
18/23
Holistic 3D Model
• Holistic 3D plant model during early stage
• Detection of collisions
• Optimal position for equipment
• High detailed piping isometrics and bill of materials
• Analysis of required space
• Optimization of 3D layout
19/23
Benefits:
• Lowers risk of wrong or unfavorable positioned equipment, valves
or instruments
• Optimal use of building space
• Early simulation / detection of down times and mistakes
• Shorter installation time
• Maintenance and working procedures can be tested
• Quality will be improved and unplanned additional costs will be
reduced
CMP VIRTUAL REALITY
• Possibility to test the positions of all equipment s
• Check of correct position of valves and instruments
• Simulation of building concepts
• Check of easiness of equipment maintenance
• Only if the planned factory has passed the practical test,
it is ready for real execution
• Integration / Simulation of improvements
20/23
CMP VIRTUAL REALITY
21/23
VR for evaluation of engineering results
VR for intuitive planning processes
Process
Simulation
3D
Model
Interconncetivity
Interconnectivity for the best possible solution
3D
Mapping
VR
CFD
Analysis
Logistic
Simulation
DOCC Tool
(Prod. Plan)
Virtual
Commissioning
Automatization
• Use of synergetic effects and combination of
systems to maximize the planning process
output.
Innovative modern plant design
22/23
Project Timeline
Quality
Future safety
Efficiency
Costs
Time
Errors
+
-
Virtual Reality Tool
Benefits on project timeline
2D Layout
Holistic 3D Model
Project timeline
3D Mapping Tool
3D Mapping Tool
CFD Analysis
Logistic Simulation
DOCC Tool (Business case study / production plans)
CAPEX Engineering
effort
Virtual Commissioning
23/23
CONTAINER GLASS
GLASS WOOL
E-GLASS
TABLEWARE
SPECIAL GLASS APPLICATION
Innovative Glass Plant Design
“In Time, Budget and Scope”