CONTAINER GLASS

GLASS WOOL

E-GLASS

TABLEWARE

SPECIAL GLASS APPLICATION

“Digital and Simulated

Glass Plant Design”

cm.project.ing GmbH is your independent consultant in the glass industry that supports you optimal and holistically in project management

as well as in engineering of major industrial projects.

Innovative Glass Plant Engineering and Project Management

Additionally the cm.project.ing is member of

several glass organizations to be up to date

for new technologies and to increase the

know-how of the company.

CMP - INTRODUCTION

01/23

RISK

Low Grade of

Automation

High

Investment

Costs

Profitability only by

High Operation Efficiency

Engineering Phase

HOLISTIC PLANT LAYOUTING

02/23

costs for

• raw materials

• energy

• labor

availabilities

• energy

• local supply

Concept Phase Definition of Basic Parameters

Fixed Tech. Data Sheet Layout

CAPEX Time Schedule

OPEX

technical data sheet

plant configuration

production planning

• IS Machines

• followers

• packaging

2a

prelim. eng. spec. core / utilities

prelim. civil + architect. spec.

plant organization

balances

Evaluation of Results

Optimal plant layout

High flexibility

Cost optimized

High quality

Optimal process efficiency

1

2b

3

4a

5

environment

norms + standards

geological data

Budget Time

4b

4c

tonnage

portfolio

7

6

Quality

Logistic Simulation

3D Mapping

Tool

CFD Simulation

Production Plan

Calculation

CMP DOCC Tool

CMP VR Tool

Logistic

Simulation

3D Model

3D Mapping

Tool

CMP VR Tool

CFD Simulation

OPTIMIZED PLANT

LAYOUT

Input

Processing, Simulation,

Validation

CUSTOMER NEEDS

PRODUCTION STRATEGY

BOUNDARY CONDITIONS

HOLISTIC 3D MODEL

CMP DOCC TOOL

LOGISTIC SIMULATION

ARCHITECTURE

CFD VISUALIZATION

CMP VIRTUAL REALITY

INVEST COSTS

OPERATING COSTS

PURCHASE & CONTRACT STRATEGY

FLEXIBILITY

PROCESS SAFETY

MAINTENANCE

IN- & OUTBOUND LOGISTIC

AREA USE

ENVIRONMENT

FUTURE EXPANSION

CONSUMPTION

Engineering Experience

QUALITY

CRITERIAS

ANALYSIS, PROCESSING

& SIMULATION INPUT

PROJECT TIMELINE

Benchmarking

PROCESS EFFICIENCY

07/23

Invest CostsOperational

Costs

FutureExpansion

Process Safety

Flexibility

Maintenance

In- & OutboundLogistic

Area Use

Environment

ProcessEfficiency

Quality

Innovation

Process

Simulation

3D

Model

Interconncetivity

Interconnectivity for the best possible solution

3D

Mapping

VR

CFD

Analysis

Logistic

Simulation

DOCC Tool

(Prod. Plan)

Virtual

Commissioning

Automatization

• Use of synergetic effects and combination of

systems to maximize the planning process

output.

Innovative modern plant design

22/23

HOLISTIC PLANT LAYOUTING

Low

Capex Low

Opex

High Flexibility

High

Efficiency

High Product

Quality

Regulations

The determination and focus of

the factory have to be clear

03/23

Invest Costs

Operational Costs

Future Expansion

Process Safety

Flexibility

Maintenance

In- & Outbound Logistic

Area Use

Environment

Process Efficiency

Quality

Innovation

HOLISTIC PLANT LAYOUTING CRITERIAS OF PLANT LAYOUTING

WE STAND WITH OUR

CUSTOMER FROM THE

ORIGINAL IDEA TO THE

START UP OF THE GLASS

PLANT

Plant design is the combination of

different aspects

06/23

Invest Costs

Operational Costs

Future Expansion

Process Safety

Flexibility

Maintenance

In- & Outbound Logistic

Area Use

Environment

Process Efficiency

Quality

Innovation

HOLISTIC PLANT LAYOUTING OPTIMIZED PLANT LAYOUT

CURRENT PLANT STATUS

OPTIMIZED CONCEPT

• Increase of product quality - CFD air flow simulation

• Huge increase of process efficiency - CFD visualization

- Technology comparison

- Logistic simulation

• Increase of flexibility - Intelligent storage solutions

- Product portfolio extension

• Increase of possibilities of future expansion - Intelligent use of space

- Synergetic concepts in utility systems

• Hugh increase in maintenance efficiency

- New workshop concepts

- Walkway analysis

• Increase in In- & Outbound logistic - Dynamic logistic concept simulation

• Less operational costs - Reduction of energy consumption

- Avoidance of down times

• Hugh Increase in innovation - Higher degree of automation

- Avoidance of down times

+15

+25

+20 +25

+10

+20

+15

+5

+15

+25

+25

+20

+15

+20

+10

09/23

-5

+45

+45

HOLISTIC PLANT LAYOUTING

Not enough loading ramps for

trucks

Workshops far away from the

production building

Additional compressor building

Cooling towers too close to

production building Compressors in the basement -

> closer to compressed air

consumers

Crossing in- and outbound

traffic

Optimized loading area for

trucks

No crossing in- and outbound

traffic

Workshops close to machines

Higher efficiency of cooling

towers

Optimized glass plant layout Ordinary glass plant layout

08/23

Step 1: Production planning

Analysis of production demands / targets per line

Analysis of product portfolio

Development of optimal machine configuration

Visualization of plant utilization grade (min, max,

average)

Calculation of expected plant output (sellable

production)

Production target parameters create the framework

for all further planning steps 10/23

Step 2: Operational cost calculation

Simulation of entire production year

Development of labor structure

Detailed calculation of operational costs (labor, raw

material, energy, consumables, maintenance, etc.)

CMP PRODUCTION PLANNING TOOL

CMP DOCC TOOL

LOGISTIC SIMULATION

Planning of internal logistic:

• Simulation and analysis of walkways

• Maintenance simulation

• Downtime detection

• Optimization of production process

• Products and raw materials logistic

• Combination of tasks

0

1

2

3

4

5

6

7

8

Maintenance Shift changes Product changes

wal

kway

/ w

ork

er [

km]

Walkway analysis

Unoptimized Optimized layout Optimized layout + workflow

A simulated and optimized internal logistic

reduces unnecessary distances for routine tasks.

= Faster job changes

= Faster maintenance

= Higher staff crew efficiency.

“Working instead of walking“

SDZ GmbH SDZ GmbH

Total time saved / worker:

2,8 km = 33 min

0,6 km = 7 min

2,1 km = 25 min

- 2,8 km

- 0,6 km

- 2,1 km

11/23

LOGISTIC SIMULATION

Planning of storage capacities:

• Dimensioning of storage areas and buffer

• Simulation of internal product logistic

• Evaluation of different layout concepts

• Increase of warehouse turnover

An optimized internal storage logistic reduces the required

storage capacity and decreases costs!

Higher warehouse turnover = Decrease of storage time = Decrease of storage costs =

Reduction of committed capital

SDZ GmbH

SDZ GmbH SDZ GmbH

12/23

LOGISTIC SIMULATION

Simulation of internal and external plant traffic:

• Optimization of in- and outbound logistic

• Dimensioning of waiting areas

• Faster processing of deliveries

• Simulation of fluctuating arrivals

• Evaluation of future scenarios

• Reduction of impairment for the local population

An optimized internal plant traffic reduces unnecessary waiting

time, traffic jams und storage capacities!

Optimal integration of the plant location into the local

infrastructure without negative effects on the local infrastructure!

SDZ GmbH SDZ GmbH

SDZ GmbH

Waiting area Analysis

13/23

SD

Z G

mb

H

CFD VISUALIZATION

To see is to understand

• Visualization and analysis of air flows inside production

buildings

• Heat emission calculation

• Evaluation of different building concepts in early stage

Detailed analyses of air flows in an early stage can avoid

negative influences on the production process.

14/23

CFD VISUALIZATION

An equipment or opening at the wrong position

can cause unintentional air flows that effect the

production process in a negative way.

• Warm or cold air streams

• Air residence time

• Heat transfer

• Insufficient air supply for equipment and processes

• Air quality

• Smoke spreading

15/23

3D AERIAL SCANNING

• Fully automated aerial 3D scanning

• GPS coordinated movement of quadcopter

• Creation of high detailed 3D model of the landscapes and buildings

• Visual analysis of height differences of the landscape

• Analysis and calculation of volumes for civil works

• Early estimation of earth movement demand

16/23

Holistic 3D Model • Holistic 3D model of glass plant vs. construction site at early stage

17/23

Holistic 3D Model • Holistic 3D model of glass plant vs. construction site at early stage

18/23

Holistic 3D Model

• Holistic 3D plant model during early stage

• Detection of collisions

• Optimal position for equipment

• High detailed piping isometrics and bill of materials

• Analysis of required space

• Optimization of 3D layout

19/23

Benefits:

• Lowers risk of wrong or unfavorable positioned equipment, valves

or instruments

• Optimal use of building space

• Early simulation / detection of down times and mistakes

• Shorter installation time

• Maintenance and working procedures can be tested

• Quality will be improved and unplanned additional costs will be

reduced

CMP VIRTUAL REALITY

• Possibility to test the positions of all equipment s

• Check of correct position of valves and instruments

• Simulation of building concepts

• Check of easiness of equipment maintenance

• Only if the planned factory has passed the practical test,

it is ready for real execution

• Integration / Simulation of improvements

20/23

CMP VIRTUAL REALITY

21/23

VR for evaluation of engineering results

VR for intuitive planning processes

Process

Simulation

3D

Model

Interconncetivity

Interconnectivity for the best possible solution

3D

Mapping

VR

CFD

Analysis

Logistic

Simulation

DOCC Tool

(Prod. Plan)

Virtual

Commissioning

Automatization

• Use of synergetic effects and combination of

systems to maximize the planning process

output.

Innovative modern plant design

22/23

Project Timeline

Quality

Future safety

Efficiency

Costs

Time

Errors

+

-

Virtual Reality Tool

Benefits on project timeline

2D Layout

Holistic 3D Model

Project timeline

3D Mapping Tool

3D Mapping Tool

CFD Analysis

Logistic Simulation

DOCC Tool (Business case study / production plans)

CAPEX Engineering

effort

Virtual Commissioning

23/23

CONTAINER GLASS

GLASS WOOL

E-GLASS

TABLEWARE

SPECIAL GLASS APPLICATION

Innovative Glass Plant Design

“In Time, Budget and Scope”