PROJECT SUMMARY

The client planned to install additional equipment to increase production capacity within an existing manufacturing facility. The available installation space was limited, while production needed to remain operational at full capacity for most of the project.

The installation therefore required careful planning to minimize production downtime, coordinate the installation of large and heavy equipment, and maintain a high level of safety throughout the project.

PROJECT DESCRIPTION

The project team, consisting of representatives from the installation contractor and the manufacturing plant making the investment, required additional support during the pre-planning and planning phases.

Our role was to support the team through the creation and analysis of accurate 3D data, virtual simulation of the installation process, and preparation of technical documentation.

Main Project Challenges

• Limited space within the installation area.
• Large-scale and heavy equipment to be transported and installed.
• Communication and coordination with the process equipment vendor.
• Working-at-height and hot-work activities.
• Installation activities performed while production remained operational.
• A short implementation schedule for the investment.
• The need for clear documentation for future operation, learning, and maintenance.

PROJECT GOALS

The primary goals were to reduce planning and installation time, complete the installation without incidents, and minimize production downtime during project implementation.

APPROACH

Our approach combined 3D laser scanning, CAD modeling, virtual analysis, installation simulation, and technical documentation.

1. DIGITALIZATION

The first stage was to create an accurate digital representation of the installation area, existing equipment, installations, and planned process equipment.

We performed 3D laser scanning of the installation area to capture the existing conditions with high accuracy. The collected point cloud data was processed and used as a reference for creating CAD models of the existing environment.

The digitalization process included:

• 3D laser scanning and measurement of the installation area.
• Point cloud processing and registration.
• Creation of preliminary and detailed CAD models.
• Modeling of existing equipment and installations.
• Creation of 3D models of new process equipment, mechanical installations, and electrical installations based on available 2D drawings, specifications, and vendor information.

This provided the project team with a common 3D environment representing both the existing facility and the equipment planned for installation.

2. SIMULATION AND ANALYSIS

After digitalizing the existing conditions and integrating the planned equipment into the 3D environment, we used the combined model to analyze the installation before work began on site.

This allowed the project team to review potential spatial conflicts, equipment movements, installation sequences, access requirements, and safety considerations during the planning phase.

3. COLLISION, MOTION, AND SAFETY ANALYSIS

Collision Analysis

We performed collision analysis between the existing facility and the new equipment to identify potential spatial conflicts before installation.

During this process, a part of the new equipment was identified as conflicting with an existing roof beam. Because the issue was detected during the planning and design phase, the team was able to address it before installation, reducing the risk of delays associated with on-site discovery, redesign, reconstruction, and additional delivery time.

Motion Analysis

Motion analysis was used to plan how large equipment would be transported, positioned, and installed within the restricted available space.

We analyzed equipment movement, required clearances, installation areas, activity sequences, and the space necessary to perform individual operations.

The simulations also supported activity sequencing by identifying which operations could be performed in parallel and which activities required temporary production shutdowns. Activities requiring a production stop could therefore be coordinated within the same shutdown window wherever possible.

Safety Analysis

The planned installation sequence was reviewed from a safety perspective, with particular attention to working-at-height activities, hot work, equipment movement, and operations performed close to active production areas.

The virtual environment allowed the team to review the planned activities before execution and develop safer working methods while considering both installation efficiency and site constraints.

4. TECHNICAL DOCUMENTATION

We prepared 2D and 3D technical documentation to support installation, future maintenance, and understanding of the equipment and systems incorporated into the project.

The documentation provided visual representations of equipment, components, assemblies, and systems together with relevant technical information.

The 3D data was organized and optimized to make it easier for the project and maintenance teams to access, review, and use within their preferred digital environment.

5. AS-BUILT CAD MODEL

Following installation, we created a complete As-Built 3D CAD model representing the equipment and installations incorporated into the production process.

The model included modifications made during installation that differed from the detailed design.

For critical parts of the installation, 3D laser scanning was also used to inspect and document the completed condition. The resulting data provided an accurate digital record of the installed systems and could be compared with the project CAD/BIM information.

6. BOQ DOCUMENTATION

For archiving, maintenance, and internal learning purposes, we prepared BOQ documentation containing visual representations and structured information about relevant parts, assemblies, equipment, and systems.

Depending on the available project information, the documentation included details such as manufacturer, component name, technical characteristics, and other useful equipment and vendor information.

RESULTS

Our 3D-based approach supported the project team throughout planning and installation and helped the client implement the production expansion while managing the constraints of an operational manufacturing facility.

The 3D CAD model of the installation area provided a common visual reference that improved communication between the teams involved in the project.

Sharing accurate CAD information about the existing installation area also improved coordination with the process equipment vendor. The vendor could use the existing-condition data as a reference when developing the equipment design, helping the project team identify and resolve integration issues earlier.

Collision analysis identified potential spatial conflicts before installation. One significant issue involved a part of the planned equipment conflicting with an existing roof beam. Detecting this during the planning phase allowed the issue to be addressed before it became an installation-site problem.

Motion analysis supported the planning of equipment transport and installation activities within the restricted space. It also helped the team coordinate parallel activities and organize operations requiring production shutdowns within limited time windows.

Safety analysis provided an additional opportunity to review installation activities before execution, particularly working at height, hot work, and equipment movement. According to the project outcome, the installation was completed with zero incidents.

The final 2D and 3D documentation provided the team with an organized technical reference for future learning, inspection, and maintenance activities.

CONCLUSION

According to the project results, the investment of approximately $1.2 million achieved its return in approximately 0.9 months instead of the initially expected three months, supported by increased production demand following handover.

The project was completed with zero incidents and approximately 48 hours of total production downtime.

By combining 3D laser scanning, CAD modeling, collision detection, motion analysis, virtual installation planning, safety review, and As-Built documentation, we helped the project team identify potential issues earlier, improve communication between stakeholders, optimize the installation sequence, reduce production disruption, and maintain a high level of safety throughout the project.