When it comes to cataloguing and detailing a factory layout, making mistakes or discovering errors too late in the design process can cost tens of thousands of pounds in lost time and rework.
Unfortunately, layouts aren’t always accurate or updated, which creates a degree of uncertainty when it comes to the installation of new equipment and rebuilding facilities. It also leads to waste in movement when employees have to go out on-site to perform measurements, take pictures and write down notes to remember important details to avoid errors.
The good news is that laser scanner technology can generate several possibilities for manufacturing industries. The technology can be profitable, and today’s modern point cloud software and applications support the work of the layout design process with great speed and efficiency.
Laser Scanning Put to the Test
The power of 3D laser scanning was demonstrated recently when London-based Red Laser Scanning, a measured building survey and 3D laser scanning company that provides service for the architecture, construction and infrastructure industries, offered their professional expertise to a ROCKWOOL Ltd factory in Wales. With one factory in Bridgend, South Wales and over 500 employees across the UK, the company provides a full range of high-performing and sustainable insulation products for the construction industry.
In this particular case, the company sought to document a 9,585 m2 area of their South Wales facility in order to establish the interfaces with the equipment upgrades needed as part of their as-built capture and modeling.
In order to achieve that aim, Red Laser Scanning used a FARO® Focus Premium Laser Scanner, a FARO® Focus S70 and a total station. Scans were registered — registration is the process of aligning multiple scans in a parent coordinate system using reference positions common between scan — using target registration with spheres, checker boards, and manual targets. Red Laser Scanning also applied survey control.
One of the projects key challenges included measuring the factory’s confined spaces with the Focus scanner since most of the equipment was placed close to each other. In order for Red Laser Scanning to capture all the required details they had to take many extra scans, positioning the scanner in the gaps between the equipment.
The Results Are In
Thanks to the company’s expertise and FARO technology, including hardware, software and its cloud-based SaaS collaborative platform, the project was successfully brought to completion with the delivery of a point cloud of the area in question.
Data processing and registration took place in FARO SCENE Software and was delivered in Autodesk® RECAP (.rcp) format. SCENE enables users to create impressive 3D visualisations of real-world objects and environments and export that data in various formats. Red Laser Scanning also benefited from its use of FARO WebShare, a web-based project management tool.
Once again, the varied tools Red Laser Scanning brought to the project proved their worth across a variety of metrics, including data visualisation and communication, the ability to gather detailed information fast, and simulation and verification of that data.
Nick Forrest, the company’s Business Development Manager, elaborated further, highlighting additional advantages to using FARO technology:
- Point cloud power — The point cloud is an excellent information carrier and can easily be used as a visualisation aid for meetings or simply to refreshing memories of a location. It also provides the possibility to view and examine a location remotely.
- Formidable measuring possibilities — The measuring possibilities allow single point and distance measurements without the concern of interfering with objects. This method can, to some extent, replace the current approach in measuring buildings and floor flatness.
- Sophisticated software — Software like SCENE can perform advanced simulations and verifications of existing and future layouts, models and installations. Additionally, parts of the point cloud can be colorized, hidden, removed, duplicated or transformed and existing 2D layout drawings or 3D models can be attached and verified relative the point cloud. And the attached objects can be simulated with clash collision or differencing.
Future FARO Success
Ultimately, the Red Laser Scanning team said that the ROCKWOOL project was brought to completion significantly faster by employing FARO 3D laser scanning technology, specifically the Focus scanner, saving the company a considerable amount of money. ROCKWOOL, too, gained a notable advantage and said it plans to rely on Red Laser Scanning for future facility upgrades and enhancements.
“We aim to build long-lasting relations with industry professionals, by delivering efficient service, high-quality and accurate as-built drawings and models, and a flexible approach,” said Pawel Sipta, Red Laser’s Managing Director. “And the FARO Focus Premium Laser Scanner helps us achieve that goal.”