Building a Connected Shop

USING DATA TO POWER PROCESSES FROM MEASUREMENT TO INSTALLATION

BY CHIP MARTIN • HEXAGON

It can often seem like manufacturing processes are forever in flux and hovering on the precipice of the next big thing, but the unwavering goal of any manufacturer is to gain efficiency. While processes have evolved astronomically since the first nail was hammered into a piece of wood, the purpose of any process change was and continues to be reaching the finish line more quickly, easily, and profitably. Thankfully, the age of information affords us opportunities to make gains not just by building more efficient hammers, today’s state-of-the-art machinery notwithstanding, but by collecting and using data to accomplish more at the front end of projects to simplify downstream tasks and increase profits on future jobs.

Digital tools that improve processes at different stages of production enable manufacturers to connect those processes without re-creating data by utilizing a single source of information from start to finish. Regardless of how and at what rate a company is able to connect its digital processes, manufacturing is in the midst of a sea change with data at its heart.

Regardless of how and at what rate a company is able to connect its digital processes, manufacturing is in the midst of a sea change with data at its heart.

LAYING AN ACCURATE FOUNDATION In their ongoing quest to achieve greater productivity, manufacturers are increasingly aware that the foundation of any successful project is laid with accurate information. In other words, bad or incomplete data is the hill upon which projects often die amid a rapidly dwindling return on investment. With this in mind, it’s no surprise that portable devices used to scan spaces in which projects will be installed have gained popularity because they ensure accuracy and are affordable.

Available in several configurations, three-dimensional (3D) laser scanning and measurement tools can be hand-held or mounted to a tripod, making it easy for one person to perform accurate distance measurement on site. Collected data sets are imported directly into computer-aided design (CAD) or design-to-manufacturing software. Files imported into CAD software display measurement points that can be used as snap guides to draw projects by hand. Additionally, measurements captured by portable devices can be used in conjunction with CAD software to verify the dimensions of designs based upon architectural drawings. Laser scanners can also be used to mark and project stud locations for hanging panels, which is a significant benefit for matching panel clips with studs for faster and easier installation.

The benefit of using scanning devices is less about saving time and more about reducing labor and error. It eliminates manual data entry and the need to send employees back to job sites to re-measure spaces when problems arise. Even if on-site measurement takes longer with a scanning device, it enables a traditionally twoemployee job to be completed by one person, and the data collected can be easily referenced as needed. As mistakes can be costly in both materials and time, manufacturers are willing to embrace technologies that ultimately pay for themselves by ensuring that expensive errors linked to measurement inaccuracies simply don’t occur.

BUILDING A CONNECTED SHOP Once foundational job data is collected, that information can be used to drive each subsequent process forward without reentering it and other vital job data at each step. Ensuring that “a single source of truth” is referenced for all production processes improves collaboration, saves time, and reduces the opportunity for error. It’s worth noting, however, that compatibility and even interoperability between systems are essential to ensure that data isn’t lost in translation.

The benefit of using scanning devices is less about saving time and more about reducing labor and error.

Ideally, ERP (enterprise resource planning) and MES (manufacturing execution system) systems should be compatible with CAD and computer-aided manufacturing (CAM) software to establish a digital thread that begins with quoting, design, and field verification and ends with assembly and installation. The number of digital tools at our disposal makes it easier than ever to customize processes to fit the needs of businesses and their preferred working methods. When preparing to build a connected solution, manufacturers should select vendors equipped to meet the current needs of their shops and provide support as they expand or gain new capabilities.

The variability of preferred processes means that there is no one-size-fits-all solution. Quotes, for instance, can be generated using an ERP system, independent estimating software, a production planning solution, and even CAD or CAM software. A solution with dedicated quotation functions is best suited to recording information on materials, such as level of quality and grade, size in linear feet and square footage per panel, whether a grain match is required, and other important data.

While planning, quotation, and production tools vary among systems, quotation data entered or imported into an MES system is generally used to manage every aspect of a job, including estimations, materials, and inventory. In addition, this data can be shared with CAM software to generate the G-code needed to produce jobs without re-entering information.

Making a seamless transition from design to production is faster and easier with applications that include both CAD and CAM functions, as this enables users to achieve both tasks within the same system. A CAD/CAM system capable of processing assemblies, such as multi-faceted wall panels, is preferable because it eliminates time spent breaking assemblies down into individual parts for the manual application of toolpath.

POST-PRODUCTION BENEFITS Establishing a connected solution that supports projects through installation goes a long way in ensuring that projects don’t hit sizeable snags once they make it off the router and into assembly and the job site. Software that generates reports and instructional printouts with graphical representations of projects helps assembly teams construct jobs correctly the first time. Software capable of producing labels that match laser projections of completed parts goes yet a step further in ensuring that installations run smoothly.

Perhaps most importantly, the ability to collect and record data enables manufacturers to better plan where they’re headed by reviewing where they’ve been. MES systems, for example, can be used to record how much time, labor, and materials were devoted to a project versus the amount estimated to determine actual profit margins. If activities are correctly recorded, it’s much easier to understand how profits are lost and where adjustments can be made. In addition, understanding where time and money are actually spent empowers manufacturers to make better business decisions while confidently planning for a more productive tomorrow.

For more information, visit hexagonmi.com.

Chip Martin is market and product manager for wood, stone and composites at Hexagon’s Manufacturing Intelligence Division.

SURFACE & PANEL • Q1 2022