3D visualization

Visualization: A picture is worth a thousand words – creating digital twins of production systems in 2D or 3D

Whether it’s a microchip or a passenger plane: manufacturing products is a complex process. The production process must be meticulously planned and thought through before even a single component finds its fixed place based on the design drawings.

Visualization is playing an increasingly important role in this process. Entire production facilities, individual production lines or even just specific work steps can be digitally reproduced and simulated using 2D or 3D models. This allows potential problems, bottlenecks or optimization potential to be identified and avoided at an early stage, even before real production starts.

For example, an automotive plant is planning a new production line for a specific model. Instead of building expensive prototypes and carrying out elaborate test runs, the production line can be mapped virtually – as a digital twin – using 2D or 3D visualization. This allows engineers to test different layouts, simulate the movement sequences of robots and optimize the material flow – all on the computer before even a single physical action takes place in the real factory.

This digital mirror image makes it possible to later increase efficiency in production, minimize errors and ultimately save time and costs. What’s more, communication between individual departments, as well as with customers and partners, is simplified if everyone involved can access the same, easily accessible “image”.

What is visualization in production?

Visualization means presenting complex information and processes with the help of visual aids in order to make them easy to understand and use. Various media and methods are used that are tailored to the specific requirements of production.

Goals of visualization

Transparency: to record the current status of production processes, material stocks, plant utilization, etc. at a glance
Communication: pass on information quickly and clearly to everyone involved
Process optimization: Identify weak points and potential for improvement in production
Error prevention: Avoid errors through clear presentation of work instructions and process sequences
Motivation and involvement: Involve employees more closely in process optimization through visual representations

Areas of application in production:

Production planning and control: visualization of key production indicators (KPIs), order progress, material flow, etc.
Shop floor management: visualization of work schedules, machine occupancy, quality data, etc. directly at the workstations
Logistics: visualization of stock levels, material movements, delivery dates, etc.
Quality management: Visualization of quality data, error rates, inspection results, etc.
Maintenance and servicing: visualization of maintenance schedules, system statuses, fault messages, etc.

Visualization methods and media:

Key figure boards: Presentation of KPIs using diagrams, tables and traffic light systems
Digital displays: Presentation of dynamic information in real time, e.g. production progress, machine status, etc.
Andon systems: Visual and acoustic signaling of status messages or faults in production
Process visualization: Representation of process sequences using flow charts, swim lane diagrams, etc.

Advantages of visualizations in production

Improved communication and collaboration
Increased production efficiency
Reduction of errors and waste
Increased transparency and control
Improved decision-making
Increased employee motivation

How do companies that visualize with digital 2D and 3D software benefit?

2D and 3D visualizations play a particularly important role in various areas of manufacturing companies and make a significant contribution to increasing efficiency and quality assurance.

1. 2D visualization

2D visualizations provide a two-dimensional representation of objects and processes. They are used in the form of:

- Technical drawings: They form the foundation of manufacturing and precisely define products and components in terms of geometry, dimensions, tolerances and surface finish.
- Circuit diagrams: In electrical engineering and electronics production, circuit diagrams are essential for documenting the wiring of components and the signal flow.
- Flow diagrams: They illustrate complex processes and sequences in production and help to identify bottlenecks and optimization potential.
- Layout planning: 2D floor plans and factory layouts help with the planning of production lines, the arrangement of machines and the optimization of material flows.
- Performance and consumption analyses: 2D charts on machine performance or energy consumption in real time and in time series help factory teams to eliminate recurring deficiencies and make sustainable optimizations.
- Clarity and precision: 2D illustrations are based on standardized symbols and display formats that are globally understandable and minimize misinterpretation.
- Relatively simple creation: 2D representations can be created and modified with comparatively little effort using CAD programs.
- Low memory requirements: Compared to 3D models, 2D files require significantly less storage space and are easier to manage.
- Limited spatial imagination: complex components and interrelationships are difficult to visualize comprehensibly in 2D.
- High degree of abstraction: 2D drawings require a certain level of technical understanding and experience in order to correctly interpret the information displayed.
- Limited simulation possibilities: Dynamic processes and movements can only be depicted statically in 2D and require additional explanations.

2. 3D visualization

3D visualizations offer a realistic, three-dimensional representation of objects and processes and open up new possibilities for manufacturing companies in terms of:

- Product design and development: 3D models enable the virtual design of products and components. Different design variants can be easily created, compared and simulated for their functionality.
- Virtual commissioning: Entire production plants can be virtually constructed and simulated before real commissioning takes place. This allows planning errors to be identified and rectified at an early stage.
- Robot programming: The programming of industrial robots is simplified and made safer by 3D simulations. Robot movements and gripping processes can be programmed and optimized offline before they are used in the real environment.
- Education and training: 3D models and simulations offer an effective way of training employees on new machines and processes. In this way, the handling of complex systems can be trained safely.
- Improved spatial understanding: complex geometries and interrelationships can be grasped intuitively using 3D visualizations, facilitating communication between those involved.
- Early detection of errors: By simulating processes and sequences, potential errors and collisions can be identified and rectified as early as the planning phase.
- More efficient processes: Virtual commissioning and robot programming using 3D simulations reduce set-up times and increase productivity.
  Improved communication: 3D models and animations enable clear and comprehensible communication, even for non-experts.
- High effort and costs: creating 3D models and simulations involves more effort and costs than 2D visualization.
- Increased hardware and software requirements: Powerful computers and special software are required to process 3D data.
- Complexity and training: Working with 3D software requires a certain training period and specific specialist knowledge.

How does 2D and 3D visualization work in series production with E-MES from FORCAM ENISCO?

The E-MES shop floor solution from FORCAM ENISCO enables the creation of digital twins of production systems in 2D or 3D. This offers a number of advantages:

Functionality:

Object creation: visualization is based on 3D objects, which can either be imported from the standard library or created in the object editor itself.
Scene structure: By preparing objects into scenes, the real production plant can be completely mapped virtually.
Data linking: The objects are linked with production data to create a real-time model of the plant. For example, material flows, machine statuses and process progress can be visualized.

What are the advantages?

Transparency: The 3D visualization provides a comprehensive overview of the entire production, processes and movement sequences.
Error analysis: A replay function enables detailed analysis of error situations. This makes it easier to identify and rectify causes and correlations.
Fast fault assignment: Faults and messages can be assigned directly to a specific system part or machine, which speeds up troubleshooting.
Efficient planning: The 3D visualization as a digital twin serves as the foundation for simulations and planning tasks in order to optimize production and avoid bottlenecks. The editor makes visualization even more efficient.
Improved communication: 3D visualizations facilitate communication between the different areas of production and thus promote collaboration.

What are the special features?

2D & 3D visualization: In the E-MES solution, it is possible to visualize in both 2D and 3D formats, depending on requirements and needs.
Product Card App (PCA): The PCA bundles all relevant data for each manufactured product in one app. This ensures access to information on product quality, process analyses, etc. at all times.

The patented 2D and 3D visualization in the E-MES solution from FORCAM ENISCO is a powerful tool for series production with partially or fully automated processes. It increases transparency, simplifies error analysis and contributes to the optimization of production processes.

Expert opinions:

Jürgen Vischer, Head of Solution Management and Academy at FORCAM ENISCO

„With our patented 3D visualization, you create a digital twin of your systems, gain transparency and have everything in view.“