SmartTM Yard and SmartTM Production

Arne Monsholm

Vice President – Business Development

Geosystems Metrology

HEXAGON

15,000+ people

3B € revenue

3,200 active patents

Intergraph Process, Power & Marine

Industries served

Oil and Gas Chemical Power

Refining Marineand Offshore

Mining and Metals

2200 Employees

in 64 countries

550 mill USD Revenue

INTERGRAPH OFFERS SOLUTIONS FOR THE ENTIRE LIFECYCLE

BASIC/FEED DETAIL DESIGN PROCUREMENT & MATERIALS

FABRICATION CONSTRUCTION OPERATION, REVAMP &

DECOMMISSIONING

Technology members

Service members

Content members

Complementary solutions

BETTER SOLUTIONS FOR BETTER FACILITIES

Smart P&ID

Smart Instrumentation

Smart Electrical

Smart Process Safety

Smart Isometrics

SmartSketch

Engineering & Schematics

Smart 3D

PDS/Frameworks Plus

Smart Review

Smart Interop Publisher

Smart FreeView

3D Design & Visualization

CAESAR II

PV Elite

TANK

GTStrudl

FEATools

NozzlePro

Visual Vessel Design (VVD)

Analysis

Smart Materials

Smart Reference Data

Smart Spoolgen

Smart Construction

Smart WQMS

Smart Production powered by Nestix

Procurement, Fabrication &

Construction

Alliances

& Partners

INTEGRATION AND INFORMATION MANAGEMENT

SmartPlant Foundation, Smart Data Validator, Smart Fusion, Smart Basic Integrator

Automation and implementation services

Typical Fabrication Facility Challenges

CAD System

formats

Material

Production

Flow

Change

Management

Available

Resource

usage

Schedule Quality

Remnant &

Material

Management

Real

Time

Information

Work Process based solutions

Catalogues & Materials

Shop Floor

Mgmt

Digital BOMWelds & QC

2D & 3D Design

Project Control

Documents & Data

ConstructionPlanning System Completion &

Handover

Virtual Assembly

DOCUMENTMANAGEMENT

PLANNING DATA & ESTIMATION

MATERIALMANAGEMENT

COMMISIONING AND TESTINGYARD ENGINEERING

SYSTEM COMPLETION

SYSTEM & SUB-SYSTEM DEFINITION

PRE-MECH.COMPLETION

MECHNICALCOMPLEION

CHECKLIST MANAGEMENT

PUNCH LISTMANAGEMENT

MATERIAL

CATALOG MANAGEMENT

BOM MANAGEMENT

PURCHASE REQUISITION

SUPPLIER MANAGEMENT

PURCHASE ORDER

SUB CON. MANAGEMENT

MATERIALRECEVING

WAREHOUSE MANAGEMENT

MATERIAL ISSUE

SHOP FLOORMANAGEMENT

WELD QUALITY MANAGEMENT

WELDER DATABASE

MATERIAL VERIFICATION

FIT-UP

MANAGEMENT OF VISUAL INSPECTION

NON DESTRUCTIVE TESTING

POST WELD HEAT TREATMENT

PROGESS

DATA & DOCUMENT MANAGEMENT

HANDOVER DATA/DOCUMENT

HANDOVER DOSSIER TREE

DOCUMENT MANAGEMENT

ASSET DATAMANAGEMENT

ENG. CHANGEMANAGEMENT

PROGRESS

ONLINE MARKUP

ELECTRONIC WORKFLOWS

TRANSMITTALS

CONSTRUCTION

MATERIAL ENGINEERING

SCHEDULE

WORKPACK CREATION

RULES OF PROGRESS

CONSTRUCTION PLANNING

4D ANIMATION

2D AND 3D REPORTING

MANAGEMENT DASHBOARD

PRODUCTIONMANAGEEMNT

NESTING –PLATE/PROFILE/PIPE

PANEL WELDING

QUEUE MANAGEMENT

INTERNALLOGISTICS

LOAD BALANCING

MACHINEINTERFACE

REMNANTMANAGEMENT

PROJECT CONTROL

BUDGETTING AND FORECASTING

CONTRACT MANAGEMENT

CHANGE CONTROL

PROGRESS

CAPITAL PLANNING

EARNED VALUE

PROGRESS MANAGEMENT

2D/3D MODEL SPOOLING

ISOMETRIC DRAWING

SPOOL DRAWING

BiILL-OF-MATERIAL

PIPE CUT LENGTH

WELD DETAILS

REPORTING

SCHEMATIC INTEGRATION

STRUCTURE

OUTFITTING

CABLE ROUTING& MANAGEMENT

PRODUCTION PLANNING

PRODUCTION DRAWINGS

DESIGN ANALYSIS

SCHEMATICS

PIPING & HVAC DIAGRAM

SINGLE LINE DIAGRAM

SINGLE LINE DIAGRAM

POWER DISTRIBUTION

INTRUMENTS INDEX

WIRING

CONSTRUCTION MANAGEMENT

WELD QUALITY MANAGEMENT

SCAFFOLDING

LIFTING LUGS

TRANSPORTATION SUPPORT

WORKPACK AUTOMATION

ESTIMATION &BUILDING STRATEGY

PRODUCTION PLANNING

DIGITAL BOM

Supporting the fabrication process flow

Engineering data

Work management

Prefabrication

Work preparation

Assembly structuresPart geometriesSchedule

Production routingCapacity planningPart nestingChange management

Workshop sequencing and balancingQueueing work phasesGuidance for shop floor

CuttingPart fabricationPanel and assembly productionInternal logistics

INDUSTRY 4.0Smart Factory

LEANManufacturing

INDUSTRIALINTERNET

Eliminate wasteEffective material utilization

Minimize inventoryOptimized reservation of material

Thin material flow in process

Maximize production flowDetect and control bottlenecks

Full data system integration reduces lead

times in production

Pull production from the demandProduce according to actual need

Meet customer requirementsReal time work status of production

Do it right the first timeProcess improves the quality of the whole steel

production flow

Empower workersOperators have access to ”real time” data to

make right decisions

Design for rapid changeoverTask list for each operator and autonomy to

make use of it

Partner with key suppliersSuppliers may interact electronically

Create a culture of continuous improvement

(Kaizen)Data collection and visualization

Process development

Supporting the principles of ”LEAN” production

▪ Design changes (geometry, material grade, thickness, profile type)

▪ Changes in received and forecasted material

▪ SmartProduction has embedded change management with automatic flagging and

color coding

▪ The consequences of changes in production will be controlled depending on the

status of the production and type of change

Cutting module Order module

Change Management

Material Forecast & Verification

Production Scheduling

Backwards/forwards

planningOrder

Work Queue

Scheduling Work Queue

Geometry based

Capacity Need

Calculation

Work Load

VisualizationWork Load

Comprehensive

Calendar SystemScheduling Rules

”Schedule to achieve

thin (Lean) material

flow in production”

Work Load & Work Queue

Production Scheduling (Level 4 and beyond)

Data Feedback from Shop Floor

PC

PC

PC

PC

PC PC

PC

PC

Parts fabrication

follow-up

Parts fabrication

follow-up

Sub-spools

assembly follow-up

Sub-spools

assembly follow-upFinal spools

assembly follow-up

Sub-spools

assembly follow-upFinal spools

assembly follow-upOverall production

planning & monitoringSmart

Production

Machinery:

1. Magenta - Sawing Machine

2. Green - Bevel Machine

3. Yellow - Fit-up station

4. Blue - Welding station

AUTOMATED FLAT PANEL LINE

DESIGN SYSTEM INTERFACES

PlatePart.XML

Pipe spool .IDF, .PCF, .FIX

ProfilePart.XML

Assembly .XML

Loop back .XML

Panel .XML

DXF, DSTV

Pipe Spool .FIX

Benefits of SmartProduction

CAD

Neutral

Maximize

Production

Flow

Manage

changes

Optimize

Resource

usage

Reduce

Man-hours

Improve

Quality

Save

Material

Follow Up

in Real

Time