Work Steps Solution Analysis Execution Observation Investment Savings Amortization Get your solution...
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Get your solutionGet your solutionGet your solutionGet your solution
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Get your solutionGet your solutionGet your solutionGet your solution
TubeShop Consulting ServicesTubeShop Consulting Services Planning and Execution
of an automated pipe shop with software support
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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Work StepsWork Steps
General approach to tube shop consulting projects:
Impressions of the tube shop and work processes
Commissioning of design, software development, machine manufacture and assembly
Machines, layout, software
Identification of problems, requirements
April 2012 3
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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ObservationObservation
Visit to the tube shop
Discussion with involved personnel
How are the drawings / geometries created?
How are the workers and the workflow organized?
What materials and diameters are used?
How does the material get from storage to the machines?
What machines and techniques are used?
April 2012 4
Observation process
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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AnalysisAnalysis
What is the current output and the projected output?
What problems exist in the workshop and on the administrative side?
What capacities exist at the moment and what are required?
What machines / techniques need to be used?
How do current methods need to be adjusted?
What fabrication control system is used?
What budget is available for solutions?
April 2012 5
Analysis process
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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Optimized workshop layout (2D and video)
Workshop
SolutionSolution
Streamlined and coordinated flow of material
Machine recommendations
Detailed outline of cost/benefits
Control of workshop and fabrication processes
April 2012 6
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SolutionSolution
Administrative
Integrated software framework
Generation of CNC data for all integrated machines
Creation of balanced work packages, making optimal use of capacities
Data-transfer from construction to workshop
Automated report functions
Complete overview of the fabrication status of each spool
April 2012 7
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SolutionSolution
Administrative
April 2012 7
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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ExecutionExecution
Commissioning of design and technical drawings
Purchase of machines
Manufacture of storage / transport system components
Assembly of machines and storage / transport system
Installation of an integrated software framework, incl. Operator training
Automatic data-transfer from construction to workshop
Automated report functions
Complete overview of the fabrication status of each spool
April 2012 8
Project Execution
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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ExampleExample
Drawings need to be split into spools for fabrication, based on internal parameters
CNC data for machines has to be calculated and prepared
Worksheets and part lists need to be created
Spool data has to be collated into work packages for the workshop
Work orders need to be assigned based on scheduling, material availability, manpower and machine capacities
Operators have to manually enter data into machines
Workshop personnel have to manually create status reports / documentation
Manual Data Preparation / Fabrication
April 2012 9
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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ExampleExample
Drawings are automatically split into spools using consistent logic (from the 3D system used in construction or customizable parameters)
Worksheets, Bills of Material and other documentation is created automatically
Work packages are created automatically, based on capacitices, scheduling, material
All CNC data are automatically generated, operators only need to confirm and start the machine
The fabrication status for every spool is automatically updated and accessible
Automatic Data Preparation / Fabrication
April 2012 9
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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InvestmentInvestment
Example for investment involved in optimizing a tube-shop projected to fabricate 20 projects p.a.:
April 2012 19
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Administrative side:
Tasks can be performed in significantly less time, allowing fewer engineers to perform the job
Constant status updates facilitate change management
All reports can be created automatically
April 2012 20
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Workshop side:
It will be possible to reallocate approx. half the current workshop staff to other jobs (assembly, hull welding, ec.)
Due to bending machines / flame-cutting, fewer t-branches, reducers and elbows will be needed
Automatic welding machines for fittings (flanges, reducers, elbows, t-branches)
Consistent fabrication quality facilitates testing and quality control
Increased workplace safety, reducing risk of accidents
April 2012 20
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
P1
P2
P3
P4
P1
P2
P3
P4
57,6°
57,6°
1000
367
578
685
1100
xyz
Diameter : 4“ XS Transport time : 20 minutes Cutting time : 3x09 min: 27 minutes Elbow assembly : 2*22 min: 44 minutes Elbow grinding time: 4*08 min: 32 minutes Elbow welding time : 4*22 min: 88 minutes Cut bow 57° : 2*10 min: 20 minutes Flange assembly : 2*09 min: 18 minutes Flange welding time: 2*20 min: 40 minutes Flange grinding time: 2*08 min: 16 minutes
Total: 305 minutes
Example for manual fabrication I:
April 2012 10
ExampleExample
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Diameter : 4“ XS Transport time : 3 minutes Cutting time : 4 minutes Bending time : 10 minutes Auto-flange-welding: 7 minutes Flange grinding time: 2*8 min: 16 minutes
Total: 40 minutes
Estimated savings: 265 minutes (approx. 86%)
Example for automized Fabrication I:
April 2012 11
ExampleExample
P1
P2
P3
P4
P1
P2
P3
P4
57,6°
57,6°
1000
367
578
685
1100
xyz
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
P1
P2
P3
P4
P5
P6
P1
P2
P3
P4
P5
P6
90,0°
59,0°
31,0°
1200
900
500
300
583
427
527
146
xyz
Diameter : 6“ XS Transport time : 20 minutes Cutting time 6“ : 4x15 min: 60 minutes Cutting time 4“ : 1x09 min: 9 minutes Elbow assembly : 3*28 min: 84 minutes Elbow grinding time : 6*14 min: 84 minutes Elbow welding time : 6*40 min: 240 minutes Cut bow 31°/59° : 2*15 min: 30 minutes Flange assembly : 6“ 12 minutes Flange assembly : 4“ 9 minutes Flange welding : 30+20 : 50 minutes Flange grinding time: 14+8 min: 22 minutes Assembly & welding reducer : 25+14+
8+40+30 : 117 minutes
Total: 737 minutes
Example for manual Fabrication II:
April 2012 12
ExampleExample
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Diameter : 6“ XS : Transport time : 3 minutes Cutting time : 4+5 min : 9 minutes Bending time : 10 minutes Auto-flange-welding : 6“ : 18 minutes Auto-flange-welding : 4“ : 7 minutes Flange-grinding-time: 14+8 min : 22 minutes Assembly & welding reducer : 25+40+30: 95 minutes
Total: 164 minutes
Estimated savings: 537 minutes (approx. 73 %)
Example for automated Fabrication II:
April 2012 13
ExampleExample
P1
P2
P3
P4
P5
P6
P1
P2
P3
P4
P5
P6
90,0°
59,0°
31,0°
1200
900
500
300
583
427
527
146
xyz
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
P1
P2
P1
P2
6000
xyz
Diameter : 16“ STD Transport time : 20 minutes Cutting time : 31 minutes Flange assembly: 2*20 : 40 minutes Flange welding : 2*(20+20): 80 minutes (semi-auto)
Total: 171 minutes
Example for manual Fabrication III:
April 2012 14
ExampleExample
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Diameter: 16“ STD Transport time: 4 minutes Cutting time: 12 minutes Auto-flange-welding: (both) 43 minutes
Total: 59 minutes
Estimated savings: 112 minutes (approx. 66 %)
Example for automated Fabrication III:
April 2012 15
ExampleExample
P1
P2
P1
P2
6000
xyz
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Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
Manual / Automatic Data Preparation / Fabrication
Avg. 5 spools / drawing Avg. 2000 drawings / project 20 project p.a. Drawings are split into logical spools, spool data is documented (Bills of Material, work
sheets, etc.), balanced work packages are created based on capacities and schedule.
ExampleExample
April 2012 16
Actual savings may differ, based on project details
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Administrative:
Assuming a constant amount of drawings / project, and average costs of 25 € per man-hour, at 20 projects savings of approx. 850,000 € could be feasible:
-Spool splitting is consistent and logical
-All bills of material and order forms are created automatically
-All reports are generated automatically
-All CNC data are generated and automatically transferred to the machines
-All work packages are created based automatically, making the best use of machine capacities and reducing scrap and retooling times
April 2012 20
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Bending:
Internal investigation by the customer has estimated a savings of approx. 100,000 € per project. just by using bending machines (includes cutting and grinding). Assuming a slightly lower ratio of bending (60%), it should still be possible to achieve savings of 90,000 € per project, or almost 1.8 Million € p.a.
April 2012 20
Calculation of savings due to bending machines
Number of Elbows (1 project) 5,918 elbows
60% bending 3,550 bends
Number of saved elbows (1 project) 1,368 elbows
Number of saved elbows (20 projects) 27,360 elbows
Average cost / elbow 15 €
Savings (parts) 410,400 €
Number of saved welds (1 project) 2,736 welds
Number of saved welds (20 projects) 54,720 welds
Welding costs (avg. 2hrs / elbow) 13 € /hr
Savings (welding) 1,422,720 €
Total savings (20 projects) 1,833,120 €
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Welding / Flame-cutting:
April 2012 20
Calculation of savings due to welding and flame-cutting machine
Consumption of reducers 2011 (excluding subcontractors)
Approx. 5,000 pieces
Estimated consumption of reducers (20 projects) Approx. 6,250 pieces
Consumption of tees 2011 (excluding subcontractors)
Approx. 5,600 pieces
Estimated consumption of tees (20 projects) Approx. 7,000 pieces
Total Number of welds (2 / reducer, 3 / tee) 33,500 welds
Welding time (avg. 2hrs, incl. cutting / grinding / fitting )
67,000 hours
Total costs 871,000 €
Calculation of savings due to welding and flame-cutting machine
50% reduction in tees due to flame-cutting - 14,000 hours ( 7,000 welds)
40% reduction in welding time per reducer - 10,000 hours
30% reduction in welding time per remaining tee - 6,300 hours
Total reduction in welding time: 30,300 hours
Savings: 393,300 €
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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SavingsSavings
Savings potential:
Operating costs:
-Utilities (electricity, water, sewage)
-Consumables (welding gases, pressurized air, shot-blasting material)
-Hardware, software installation, operator training
-Total operating costs: approx. 250,000 € p.a.
April 2012 20
Task Savings per Project
Per year (20 Projects p.a.)
Data preparation 42,500 € 825,000 €
Bending 90,000 € 1,800,000 €
Welding (reducers and tees) 19,665 € 393,300 €
Operating costs 250,000 €
Estimated savings 3, 018,300 €
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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AmortizationAmortization
Amortization of Investment over time – 20 projects p.a.
Profit
X-axis Time
April 2012 21
Amortization of Investment over time – 15 projects p.a.Amortization of Investment over time – 10 projects p.a.
Work Steps
Solution
Analysis
Execution
Observation
Investment
Savings
Amortization
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3R software solutions - Kleistraße 39 - 59073 Hamm - GermanyPhone +49 2381 9724 710 - Fax +49 2381 9724 711 - Mail [email protected]