Smart mODULar aSSEmBLY SOLUtION - Hexagon

Smart mODULar aSSEmBLY SOLUtIONPerfecting the Building Blocks of industry

Brochure

VENTURES

the laBours of large–scale construction

a new way to Build

solution modules

design module

workflow module

managing module

insPection module

integration

common standard infrastructure

the smart modular assemBly Process

aBout hexagon ventures

2

4

6

7

9

11

12

15

16

18

21

CONtENtS

Smart mODULar aSSEmBLY / 1

The rapid growth of nations and their economies has increased the demand for large engineering projects in every corner of the world, in nearly every major industry. Mining, oil and gas, automotive and marine are just a few of the industries in which large structures factor.

Building large structures has long been a challenge for engineers. The proper design and modularisation of the structure and its final assembly are particularly arduous tasks. Unfortunately, many construction processes are intrinsically imprecise, resulting in parts with dimensional imperfections that can potentially risk the quality, safety and use of the final product. Because safety and quality cannot be compromised, some scrap and rework in manufacturing and assembly processes is often necessary.

To minimise the risks of dimensional imprecision, control of and insight into the design and build process is mandatory. There are costs and delays associated with reworking a part, and the sooner the impact on the construction schedule is known, the better.

Smart Modular Assembly closes a gap in the construction workflow where the assembly of complex structures is critical.

The combination of design tools for proper modularisation, a managing tool for planning and “what if” scenarios, metrology instruments and analysis software can fulfill all the functionality and permit immediate feedback to the design and planning teams for them to take corrective action.

the

laBo

urs

of

lar

ge–

scal

e co

nst

ruct

ion

Smart modular assembly is built on the strength of the Hexagon global family of brands. a collaborative solution from Intergraph, Hexagon metrology and Leica Geosystems, Smart modular assembly is an innovative way to link design information to the build workflow for large-scale construction projects.

By integrating Intergraph’s SmartPlant family of products with measurement data obtained by the precision equipment and software of Hexagon metrology and Leica Geosystems, Smart modular assembly provides visibility of the dimensional quality of parts, automating and optimising processes.

It is the only comprehensive solution to connect multiple products. From single-part inspection to highly accurate, large-scale, multi-instrument surveys, the advanced analysis capabilities support large-scale manufacturers that have no other option but to make components that fit, stick to time schedules and keep costs under control.

Smart modular assembly provides a higher degree of dimensional control in manufacturing, which helps streamline processes, enabling new manufacturing technologies, reducing production time and defining higher demands for third-party providers.

With Smart Assembly, suppliers receive real-time information that allows them to anticipate and correct issues in the early stages, increasing effectiveness and output in the assembly line. Information is automatically shared among Smart Assembly modules, automating various processes including time schedule, materials logistics, manufacturing planning and more.

a new way toBuild


solution modules

the Smart modular assembly Design module provides all the capabilities needed to design modular structures including marine assets such as FPSOs (floating production storage and offloading), drilling vessels and other complex structures. all phases of the engineering life cycle are addressed by the Design module, from conceptual design to a detailed specification of parts from the various disciplines involved in the product. Based on a solid 3D model that can be exported to a wide range of file formats, the Design module can be enhanced by various software tools. the Design module is composed of data-centric, rule-driven software. the design is stored as data in a relational database. the relation between parts and design data from different disciplines is stored as rules that reflect the design’s intentions for the product. the module delivers 3D models of the parts to be assembled.

an important decision in the design of a modular structure is the size of the parts, subassemblies and blocks. this size is restricted by shop and transportation limitations. as parts become smaller, the effects of imprecision are increased. Bigger parts cannot be handled in a cost-effective way. With a better inspection process, the main dimensions of parts can be reduced without loss of dimensional quality in the assembly process, giving the designer and constructor greater flexibility.

In a mature stage of the design, the 3D model can be decorated with the inspection information. the important inspection points, surfaces and characteristics can be highlighted in the design model to help the inspector to pay special attention to the as-built conditions during measurement.

design module

design

insPection

Product definition, nominal valuesand specifications, 3D CAD model production, product structure, control structures and their relations

Equipment and software for inspection and quality control software for automatic inspection, virtual assembly, inspections reports and measurements

module functions and deliveraBles

workflow

Activities and workflow, change management process definition, engineering database and collaboration hub and documentmanagement

managing

Workforce planning, 4D simulation and construction progress manage-ment material handling, part procure-ment and tracking, project planning and work packages

6 / Smart mODULar aSSEmBLY Smart mODULar aSSEmBLY / 7

workflow module

the Smart modular assembly Workflow module creates a collaborative environment for all disciplines that are involved in a large project.

an effective collaboration demands easy communication and precision information. to accomplish this goal, an engineering database is shared by an information hub operating with a configurable workflow. all other modules can exchange information with the hub precisely and efficiently, keeping everyone connected and up-to-date on the status of every part.

the engineering database is configured to the specific needs of a project, but also has the tools to address the common

requirements of all large projects. the process workflow can be automated, providing desired speed and reliability, checking rules and verifying and managing inconsistencies.

the Workflow module of Smart modular assembly is responsible for storage of all engineering information, whether a design specification or an inspection report. all data are related to the part in the project configuration. Proper access to the correct information can be granted, streamlining the work process and leveraging collaboration.


the Smart modular assembly managing module offers a precise view of the overall construction process, and the tools to interact with the process and effectively manage design activities, procurement, supply chain and materials storage until its final assembly. a comprehensive view of the project status helps identify bottlenecks and acts at the right moment to achieve success, reducing impact on the workflow.

By seamlessly integrating subcontractors and suppliers with designers and the shop floor, this module allows easy fabrication tracking and on-site management, managing construction resources, materials and schedules. Permanent feedback of the progress and relationship of tasks is kept updated with the actual design. the managing module enforces data and material reuse and standardisation, with great improvements in storage, maintenance, procurement and quality control.

the managing module of Smart modular assembly is especially important when a project is geographically distributed, such as marine vessels and offshore structures.

managing module


10 /

insPection module

Large complex structures have many sources of dimensional errors such as the effect of heat in the cutting and welding process. Large structures are subject to deformation due to their own weight, the weather and other forces. Frequent inspection serves as an assurance of a part’s dimensional integrity.

a variety of portable instruments can be used to feed the Smart modular assembly Inspection module with as-built information. Handheld devices from Leica Geosystems and Hexagon metrology that provide this function include DIStO, total stations, laser scanners, multi-stations and HDS devices.

Each device has a special function and serves as a very precise eye of the engineer and product manager. these tools are constantly analysing and informing the user of actual dimensions and unavoidable deviations of the parts, allowing managers and engineers to make correct decisions about the part on time.

an increase in inspection speed is highly desirable by the builder, as it allows a quicker response to imperfections without compromising the overall schedule. Online and in the field, decision making is crucial in complex large-structure construction.

Smart modular assembly combines the instrument measurements with the CaD model, creating relationships between them. the 3D CaD model serves as a frame of reference for the measurements, making sense out of once sparse coordinates and making portable metrology much easier. Using the 3D CaD model as a basis for the inspection helps the measurement process by anticipating what information is relevant to the part. Bringing the measurement data back to the design enhances engineering decisions on the rework if needed or other actions. In a collaborative environment, suppliers and managers are informed earlier in the process and the project is always in control.

12 / Smart mODULar aSSEmBLY

integration

all software tools and modules of Smart modular assembly are implemented with the concept of concurrent engineering. Designers from different disciplines, external suppliers and subcontractors can collaborate whether they are in the same company, city or country. Standard import and export functionality assures that up-to-date information reaches the correct designer in time, avoiding decisions made based on deprecated information.

Smart modular assembly provides integration among tools and disciplines and phases of the project. the actual measurement of a part when constructed can reflect in the designed dimensions of other parts, and this level of integration can be achieved by the solution.

Existing engineering software, legacy systems and external control and corporative systems also can be integrated with Smart modular assembly. an open standard interface is available to help customisation and expansion of the solution.


common standard infrastructure

Smart modular assembly is built on a de facto industry standard, with off-the-shelf hardware and operating systems. all software uses available hardware equipped with microsoft Windows Operating System and a centralised database such as mS SQL Server or Oracle. this reduces the total cost of ownership of the solution and allows the infrastructure scalability with the growth of the project. this microsoft standard architecture supports the demands with a scalable solution for all sizes of projects. Web integration provides remote access to information for monitoring, control and on-site decision making. tools for customisation to specific needs are available for experienced users using standard programming languages.


the

sma

rt

mo

du

lar

a

ssem

Bly

Pr

oce

ss

Smart modular assembly is an “end-to-end” solution in the manufacturing process built upon the standards and integration of existing tools. minor configuration and automation, consulting and training in the use and data exchange within these tools also are needed to reach the full potential of the solution.

the Smart modular assembly process starts in the design phase by defining the desired dimensions of the parts and their relation. When designing for inspection, the model should include the correct points of control where the inspection should be made. While still in the design phase, the part can be divided into components for construction purposes.

Using the workflow capability, the CaD model of each part is submitted to an acquisition process. When the raw material arrives, the material managing tool can inform the shop floor to schedule the building of that part along with the inspection work package of the part using the managing module.

engineering workflow

design Planning

Procurementlogistics

constructioninspection

3d design tool

materialmgmt tool

constructionmgmt tool

3d model Partsinspection

work Package

finalassembly

inspection tool

dimensional analysis


Hexagon provides special customisation and specialised services to adapt Smart modular assembly to a company’s specific needs.

throughout the process, experts help companies reach their target degree of automation. the benefits of each module are realised through the work of specialists who adapt the solution to each need.

Hexagon also provides training for every tool and its integrations.

aBout hexagon ventures

Hexagon Ventures offers the next generation of smart solutions for business verticals. As part of Hexagon’s Innovation Hub, Hexagon Ventures benefits from the strength of focused technology and application initiatives, leveraging Hexagon’s portfolio of geospatial and industrial enterprise technologies, application knowledge and global presence. Hexagon Ventures is part of Hexagon (Nasdaq Stockholm: HEXA B; www.hexagon.com), a leading global provider of information technologies that drive quality and productivity improvements across geospatial and industrial enterprise applications. Learn more at hexagon-ventures.com.


HS0100-BR-0112v4 ©Copyright 2015 Hexagon Ventures. All rights reserved. Other brands and product names are trademarks of their respective owners. Hexagon Ventures believes the information in this publication is accurate as of its publication date. Such information is subject to change without notice.

Smart mODULar aSSEmBLY SOLUtION - Hexagon

Documents

Transcript of Smart mODULar aSSEmBLY SOLUtION - Hexagon