CoLa | Collaborative factory layout planning in brownfield projects

Development of an innovative point cloud-based planning approach

As developments in recent years show, the numbers of brownfield and greenfield factory planning projects are steadily converging. In total, more than 2,400 conversion measures requiring approval are carried out on existing factory and workshop buildings in Germany every year. It comes as no surprise that the relevance of brownfield projects has increased in recent years compared to greenfield projects. This is because the redesign of existing factory buildings offers companies a number of advantages over new construction. For example, it saves resources and protects the environment.

On the other hand, brownfield factory planning projects are also characterized by a number of specific challenges. The data on the existing factory, which forms the basis for the redesign, plays an important role in these projects. However, since this data is often inadequate in practice, planners are faced with the challenge of establishing an appropriate data basis at the start of the project. This process can be very time-consuming. In addition, communication in brownfield factory planning projects is often complicated by complex processes and a large number of participants.

The »CoLa« research project aims to address precisely these challenges with an innovative planning approach.

© Christian Strohmayr | image24.eu
Planning a factory layout in VR

Project goal – Intuitive and collaborative factory planning through the use of point clouds

The aim of »CoLa« is to enable companies to intuitively create layout planning variants in brownfield projects and evaluate them using key performance indicators.

This is intended to simplify the early planning phases of brownfield projects in particular. In addition, the planning approach developed should be both immersive and collaborative. These two goals are to be achieved by setting up a VR environment in which several project participants can make adjustments to the layout at the same time. The basis of this VR environment is a point cloud of the real factory that is to be redesigned. The intelligent use of point clouds as a planning basis is also intended to reduce the time required at the start of the project to build up a database in the form of digital factory models.

© Fraunhofer IGCV
Initial situation and objectives of the project

What's inside?

The contents of the project reflect its objectives and together form an innovative planning process that begins with scanning a factory and ends with the key figure-based optimization of layout planning. The following components are being specifically researched within the framework of »CoLa«.

© Gexcel SRL
Scanning process for generating the point cloud

Advanced processing of point clouds for further use in digital factory planning:

The aim here is to generate digital models for buildings and production systems based on point clouds, so that the actual condition of the factory can be reused as a digital model.

Planning and interaction options in virtual spaces in the context of factory planning:

The next step will be to examine the advantages and areas of application of VR in the context of factory layout planning. The use of a VR platform should enable factory layouts to be planned and evaluated collaboratively, regardless of location.

Advanced, key figure-based evaluation of factory layouts in virtual spaces:

Layout planning in virtual space should be supported by a selection of key figures, so that a reliable basis for evaluation of different layout variants is created and comparability is achieved.

Interactions between factory buildings and production systems for deriving building requirements based on specific factory layouts:

Based on the factory layouts created, requirements for the new factory layout in the building will then be derived. This will enable the conversion costs in brownfield scenarios to be assessed.

Insights into the results of initial test runs

The video shows the results of initial tests on integrating factory models into the Sideffects VR platform. It also demonstrates how CAD models of production resources can be inserted into the building model and moved around. (Video credits: Side Effects AG)

Outlook for upcoming results

© Gexcel SRL
Results: Capturing a factory building as a point cloud

The actual development work for the research project has only just begun. However, the necessary requirements have already been defined at this stage, allowing development of the individual solution components to commence. Initial tests are currently being carried out to integrate point cloud-based factory models into a VR environment. The accompanying video could be inserted here.

Further projects in the field of factory planning and digitalization

CoLa | Collaborative factory layout planning in brownfield projects

Collaborative brownfield factory planning using point clouds and VR

© Shutterstock | thinkhubstudio

With the aim of shortening the duration of layout planning while simultaneously improving the quality of the results, the CoLa project will be researching an innovative point cloud-based planning approach.
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AnomalieKI | AI-based quality assurance of cast components

© A3 | Christian Strohmayr

The aim of the AnomalieAI project is to develop an approach using Artificial Intelligence (AI) to identify anomalies in castings in order to save both costs and time.
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DAMOKLEZ | Consistently agile and model-based component development for electromobility with digital twins

© Dmytro - stock.adobe.com

In the DAMOKLEZ research project, an approach is being developed for the development of components for electromobility that enables an overarching consideration of the entire life cycle, taking into account production and operation. This results in a continuous development in a closed loop.
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Inventory digitization for the use of Building Information Modeling in existing production environments | BIMPro

© Fraunhofer IGCV | Bernd Müller

Factory environments are continuously changing and conventional planning procedures often lead to poor achievement of objectives. These challenges can be met by applying the methodology of Building Information Modeling in factory environments. As-built digitization provides the first step to create a BIM model in existing factory environments.
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Cooperation with Fraunhofer IGCV

Cooperation

Industry solutions

The key sectors of Fraunhofer IGCV:

Mechanical and plant engineering
Aerospace
Automotive and commercial vehicles