Virtual Factory Planning Optimizes Production Layout

Client Challenge

A medium-sized manufacturing company needed to reconfigure their main production facility to accommodate new product lines while maintaining existing operations. They faced several challenges with traditional planning approaches:

• Limited physical space that needed to be optimized for maximum efficiency
• Complex material flow that was difficult to visualize in 2D
• Safety concerns around equipment placement and operational zones
• Difficulty visualizing proposed changes using traditional 2D layouts
• Need to maintain partial production during the transition
• Multiple stakeholders with different priorities needed to approve the design

Traditional 2D CAD layouts and physical mockups were proving inadequate for communicating the proposed changes to stakeholders and identifying potential issues before implementation.

Our Solution

We implemented a fully interactive 3D virtual reality environment of both the current facility and proposed layouts, enabling stakeholders to experience and evaluate designs at full scale before physical changes began.

Key Features Implemented

• Digital Twin Creation: High-fidelity 3D scan of the existing facility provided the foundation for planning
• Equipment Library: Accurate 3D models of all current and planned machinery with proper clearances and utility requirements
• Material Flow Simulation: Visualization of production flows to identify bottlenecks and optimize movement
• Multi-User Collaboration: Remote stakeholders could join VR sessions simultaneously to review designs together
• Phased Implementation Planning: The VR environment included timeline capabilities to plan and visualize the transition process

Implementation Process

The implementation was completed in five phases:

1. 3D Capture and Modeling (2 weeks): Complete laser scanning of the existing facility and conversion to a usable 3D environment
2. Equipment Modeling (3 weeks): Creation of accurate 3D models for all current and planned equipment
3. Layout Development (4 weeks): Collaborative design of multiple layout options with engineering team
4. Stakeholder Reviews (2 weeks): Series of VR sessions with management, operations, maintenance, and safety teams
5. Refinement and Validation (3 weeks): Implementation of feedback, final revisions, and validation of the plan

Results

The virtual factory planning process delivered significant measurable benefits:

Quantitative Improvements

• 25% Improvement in Space Utilization: The ability to visualize and test layouts in 3D led to more efficient use of available floor space
• 15% Increase in Production Throughput: Optimized material flow and equipment placement reduced bottlenecks
• 20% Reduction in Implementation Time: The detailed virtual plan minimized rework and adjustments during physical implementation
• 30% Decrease in Change Orders: Issues were identified and resolved virtually before physical changes began

Qualitative Benefits

• Better Stakeholder Buy-in: All teams could experience and contribute to the new layout, leading to stronger support
• Improved Safety Planning: Potential hazards were identified and mitigated in the virtual environment
• Enhanced Training: The VR environment was repurposed for training operators on the new layout before changes were completed
• More Confident Decision-Making: Management could visualize options and outcomes before committing resources

Client Testimonial

"The VR factory planning process transformed how we approached our facility redesign. Being able to walk through our new layout before construction began helped us avoid several costly issues that we simply wouldn't have caught with 2D drawings. The ability to have our entire team collaboratively review multiple design options was invaluable. What impressed us most was how accurate the virtual environment was compared to the final result."

— Director of Operations, Manufacturing Company

Long-term Impact

The company has now adopted virtual planning as a standard practice for all facility modifications. The digital twin developed during this project continues to provide value:

• Used for onboarding new employees to understand facility layout and operations
• Serves as the planning foundation for smaller continuous improvement projects
• Enables visualization of future expansion scenarios
• Acts as a communication tool when showcasing production capabilities to potential customers
• Maintained as a living document that is updated as the physical facility changes

The initial investment in virtual factory planning has delivered ongoing returns well beyond the immediate project benefits.