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We understand business

We develop software. We understand business. We create processes. TubeShop Consulting Services Planning and Execution of an automated pipe shop with software support. Observation. Execution. Analysis. Solutions. Work Steps.

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We understand business

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  1. Wedevelopsoftware Weunderstandbusiness Wecreateprocesses

  2. TubeShop Consulting Services Planning and Execution of an automated pipe shop with software support

  3. Observation Execution Analysis Solutions Work Steps • General approachtotubeshopconsultingprojects: • Commissioning of design, software development, machine manufacture and assembly • Impressions of the tube shop and work processes • Machines, layout, software • Identificationof • problems, requirements

  4. Observation Observation process • Visittothetubeshop • Discussionwithinvolvedpersonnel • Howarethedrawings / geometries created? • Howaretheworkersandtheworkfloworganized? • Whatmaterialsanddiametersareused? • Howdoesthe material getfromstoragetothemachines? • Whatmachinesandtechniquesareused?

  5. Analysis Analysis process • Whatisthecurrentoutputandtheprojectedoutput? • Whatproblemsexist in theworkshopandon the administrative side? • Whatcapacitiesexistatthemomentandwhatarerequired? • Whatmachines / techniquesneedtobeused? • How do currentmethodsneedtobeadjusted? • Whatfabricationcontrolsystemisused? • Whatbudgetisavailablefor solutions?

  6. Solution Workshop Optimizedworkshoplayout(2D andvideo) Machine recommendations Streamlined and coordinated flow of material Detailed outline of cost/benefits Control of workshop and fabrication processes

  7. Solution Administrative • Integrated software framework • Generation of CNC datafor all integratedmachines • Creationofbalancedworkpackages, making optimal useofcapacities • Data-transfer fromconstructiontoworkshop • Automatedreportfunctions • Completeoverviewofthefabricationstatusofeach spool

  8. Solution Administrative • Availablereportsanddocumentation: • Worksheets • Part lists • Bill of Material • Cuttinglists (optimized) • Bendinglists • Weldingdocumentation • Surfacetreatmentdocumentation • Testingdocumentation • Insulationreports • Flushingreports • Spool weightcalculations • Dia-Inch: Shop weld • Dia-Inch: Field weld • Dia-Inch: Installation weld

  9. Execution Project Execution • Commissioningof design andtechnicaldrawings • Purchaseofmachines • Manufactureofstorage / transport systemcomponents • Assemblyofmachinesandstorage / transport system • Installation of an integratedsoftware framework, incl. Operator training • Automaticdata-transfer fromconstructiontoworkshop • Automatedreportfunctions • Completeoverviewofthefabricationstatusofeachspool

  10. Example Manual Data Preparation / Fabrication • Drawingsneedtobesplitintospoolsforfabrication, based on internalparameters • CNC dataformachineshastobecalculatedandprepared • Worksheets andpartlistsneedtobecreated • Spool datahastobecollatedintoworkpackagesfortheworkshop • Work ordersneedtobeassignedbased on scheduling, material availability, manpowerandmachinecapacities • Operators havetomanuallyenterdataintomachines • Workshop personnelhavetomanuallycreatestatusreports / documentation

  11. Example Automatic Data Preparation / Fabrication • Drawingsareautomaticallysplitintospoolsusingconsistentlogic (fromthe 3D systemused in constructionorcustomizableparameters) • Worksheets, Bills of Material andotherdocumentationiscreatedautomatically • Work packagesarecreatedautomatically, based on capacitices, scheduling, material • All CNC dataareautomaticallygenerated, operatorsonlyneedtoconfirmandstartthemachine • The fabricationstatusforevery spool isautomaticallyupdatedandaccessible

  12. Investment Example for investment involved in optimizing a tube-shop projected to fabricate 20 projects p.a.:

  13. Savings 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

  14. Savings 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

  15. 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 Example for manual fabrication I: April 2012 10

  16. 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 Example for automized Fabrication I: April 2012 11

  17. Diameter : 6“ XS Transport time : 20 minutes Cuttingtime 6“ : 4x15 min: 60 minutes Cuttingtime 4“ : 1x09 min: 9 minutes Elbowassembly: 3*28 min: 84 minutes Elbowgrinding time : 6*14 min: 84 minutes Elbowwelding time : 6*40 min: 240 minutes Cut bow 31°/59° : 2*15 min: 30 minutes Flangeassembly : 6“ 12 minutes Flangeassembly : 4“ 9 minutes Flangewelding : 30+20 : 50 minutes Flangegrinding time: 14+8 min: 22 minutes Assembly & welding reducer : 25+14+ 8+40+30 : 117 minutes Total: 737 minutes Example Example for manual Fabrication II: April 2012 12

  18. 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 Estimatedsavings: 537 minutes (approx. 73 %) Example Example for automated Fabrication II: April 2012 13

  19. Diameter : 16“ STD Transport time : 20 minutes Cutting time : 31 minutes Flangeassembly: 2*20 : 40 minutes Flangewelding : 2*(20+20): 80 minutes (semi-auto) Total: 171 minutes Example Example for manual Fabrication III: April 2012 14

  20. Diameter: 16“ STD Transport time: 4 minutes Cutting time: 12 minutes Auto-flange-welding: (both) 43 minutes Total: 59 minutes Estimatedsavings: 112 minutes (approx. 66 %) Example Example for automated Fabrication III: April 2012 15

  21. Example 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. Actual savings may differ, based on project details April 2012 16

  22. Savings Savings potential: • Administrative: • Assuming a constantamountofdrawings / project, andaveragecostsof 25 € per man-hour, at 20 projectssavingsofapprox. 850,000 € couldbefeasible: • Spool splittingisconsistentandlogical • All billsof material andorderformsarecreatedautomatically • All reportsaregeneratedautomatically • All CNC dataaregeneratedandautomaticallytransferredtothemachines • All workpackagesarecreatedbasedautomatically, makingthebestuseofmachinecapacitiesandreducingscrapandretoolingtimes

  23. Savings 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.

  24. Savings Savings potential: Welding / Flame-cutting:

  25. Savings Savings potential: • Operating costs: • Utilities (electricity, water, sewage) • Consumables (weldinggases, pressurizedair, shot-blasting material) • Hardware, software installation, operatortraining • Total operatingcosts: approx. 250,000 € p.a.

  26. Amortization Amortization of Investment over time – 20 projects p.a. Amortization of Investment over time – 15 projects p.a. Amortization of Investment over time – 10 projects p.a. Profit X-axis Time

  27. C NTACT US ü 3R software solutions Münsterstr. 5 Hamtec 59065 Hamm Deutschland Phone +49 2381 9724 710 Fax +49 2381 9724 711 E-Mail info@3-r.de 3R softwaresolutions- Kleistraße 39 - 59073 Hamm - Germany Phone +49 2381 9724 710 - Fax +49 2381 9724 711 - Mail info@3-r.de

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