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Laser scanning in manufacturing
industries
The potential and usability of laser scanning for industrial applications
JOHAN SVEDBERGER
JONAS ANDERSSON
Master of Science Thesis IIP 2013:x
KTH Industrial Engineering and Management
Industrial Production
SE-100 44 STOCKHOLM
Abstract Making mistakes or discovering errors too late in the factory layout process is very costly. Unfortunately,
the layouts aren’t always accurate or updated which creates a degree of uncertainty when it comes to
installation of new equipment and rebuilding facilities. It also leads to a lot of waste in movement when
employees has to go out in production to perform measurements, take pictures and take notes in order to
remember important details to avoid errors.
Lasers in land and engineering surveying instruments have been widely used for the last 30 years. A natural
development has been to add a scanning mechanism to a total station that were already equipped with
laser rangefinders and angular encoders, allowing automated measurement and location of thousands of
nonspecific points.
The automobile industry has begun to see the potential of laser scanning, mainly because of the
development of the software handling the scan results, the point clouds. Scania, in collaboration with the
FFI research project at the Royal Institute of Technology (KTH), therefore wanted to investigate how the
new possibilities of 3D laser scanning can facilitate the development and maintenance of production
systems and how it could be implemented in the current factory design process.
By scanning three locations at Scania related to machining, assembly and aftermarket service the usability
of the results has been investigated with the software Faro Scene and Bentley Pointools V8i.
The results of the study showed that the laser scanning technology can generate several possibilities for
manufacturing industries. The technology can be profitable and the modern point cloud software and
applications could support the work of the layout design process greatly. Three main application areas
found:
Visualization & communication: The point cloud is an excellent information carrier and can easily be
used as a visualization aid for meetings or simply to refreshing memories of a location. It also
provides the possibility to view and examine a location remotely.
Gather information: The measuring possibilities are immense, allowing single point and distance
measurements without the concern of interfering with objects. The method can to some extent
replace the current approach in measuring buildings and floor flatness.
Simulation & verification: Software can perform advanced simulations and verifications of existing
and future layouts, models and installations. Parts of the point cloud can be colorized, hidden,
removed, duplicated or transformed. Existing 2D layout drawings or 3D models can be attached
and verified relative the point cloud. The attached objects can be simulated with clash collision or
differencing.
Keywords: 3D Laser Scanning, TLS, CAD, Point Cloud, Factory Layout, Faro Scene, Bentley Pointools V8i, Factory
Design Process, Factory Scanning Process.
Sammanfattning Att göra fel eller upptäcka fel sent i fabrikslayoutprocessen är mycket kostsamt. Layouter är inte alltid
korrekta eller uppdaterade vilket kan skapa en viss osäkerhet vid installation av ny utrustning eller
ombyggnationer. Det leder också till onödiga förflyttningar då anställda måste gå ut i produktionen för att
utföra kontrollmätningar manuellt genom att ta bilder och föra anteckningar för att komma ihåg viktiga
detaljer och undvika fel.
Lasrar inom mark- och lantmäteriinstrument har använts i stor utsträckning under de senaste 30 åren. En
naturlig utveckling har varit att lägga till en skanningsmekanism till en total station som redan är utrustad
med laseravståndsmätare och vinkelgivare vilket möjliggör automatisk mätning och lokalisering av
tusentals ospecifika punkter.
Fordonsindustrin har börjat att se potentialen med laserskanning, främst på grund av utvecklingen inom
hanteringen av punktmoln, resultatet från skanningen, på mjukvarusidan. Scania, i samarbete med
forskningsprojektet FFI vid Kungliga Tekniska Högskolan, ville därför undersöka hur de nya
möjligheterna inom 3D-laserskanning kan underlätta och stödja utveckling och underhåll av
produktionssystem samt hur det skulle kunna användas i den nuvarande fabrikslayoutprocessen.
Genom att skanna tre platser på Scania tillhörande bearbetning, montering och service (eftermarknad) har
användbarheten av resultat undersökts med mjukvarorna Faro Scene och Bentley Pointools V8i.
Resultaten av studien visade att laserskanning kan skapa många nya möjligheter för tillverkande industrier.
Tekniken har visats sig vara lönsam och funktioner i moderna programvaror kan stödja arbetet för
fabrikslayoutprojektering väsentligt.
Tre huvudsakliga användningsområden hittades:
Visualisering och kommunikation: Punktmolnet är en utmärkt informationsbärare och kan enkelt
användas som en visualiseringsstöd för möten eller för att komma ihåg platser. Det ger också
möjlighet att se och undersöka en plats på distans.
Samla information: Mätmöjligheterna är goda. Punkter och avstånd kan mätas utan att påverkas av
skymmande objekt. Metoden kan även till viss del ersätta det nuvarande arbetssättet med
uppmätning av byggnader och planhet av golv.
Simulering & verifiering: Programmen kan utföra avancerade simuleringar och verifieringar av
befintliga och framtida layouter, modeller och installationer. Delar av punktmoln kan färgläggas,
gömmas, tas bort, dubbleras eller flyttas. Befintliga 2D-ritningar eller 3D-modeller kan importeras
och kontrolleras relativt punktmolnet samt att kollisionstester kan utföras.
Nyckelord: 3D laserskanning, TLS, CAD, punktmoln, Fabrikslayout, Faro Scene, Bentley Pointools V8i, Factory
Design Process, verkstadsprojektering, Fabriksskanning.
Nomenclature CAD Computer Aided Design
CAM Computer Aided Manufacturing
FOV Field Of View
GUI Graphical User Interface
HD High Definition
IPS Industrial Path Solutions
LiDAR Light Detection And Ranging
PDM Product Data Management
PLM Product Lifecycle Management
POD Point Database
PTL Project file
RGB Red, Green and Blue
TLS Terrestrial Laser Scanner
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Content 1 Introduction ......................................................................................................................................................... 3
1.1 Background .................................................................................................................................................. 3
1.1.1 Current problems at Scania .............................................................................................................. 3
1.1.2 Origin of the thesis ............................................................................................................................ 4
1.2 Purpose ......................................................................................................................................................... 5
1.3 Problem analysis .......................................................................................................................................... 5
1.4 Delimitations ................................................................................................................................................ 5
2 Methodology ........................................................................................................................................................ 7
2.1 Method model of the study ....................................................................................................................... 7
2.1.1 Finding output to RQ1 ..................................................................................................................... 7
2.1.2 Finding output to RQ2 ..................................................................................................................... 7
2.1.3 Finding output to RQ3 ..................................................................................................................... 8
2.1.4 Finding output to RQ4 ..................................................................................................................... 8
2.2 Data collection ............................................................................................................................................. 8
2.2.1 Document study ................................................................................................................................. 8
2.2.2 Interviews ............................................................................................................................................ 8
2.2.3 Observation ........................................................................................................................................ 8
3 Theoretical framework .....................................................................................................................................11
3.1 Digital factories & digital manufacturing ..............................................................................................11
3.2 Factory layout ............................................................................................................................................12
3.2.1 Layout software evaluation .............................................................................................................12
3.2.2 Factory Design Process ...................................................................................................................14
3.3 3D laser scanning ......................................................................................................................................15
3.3.1 History and background .................................................................................................................15
3.3.2 Terrestrial laser scanner ..................................................................................................................15
3.3.3 TLS technology ................................................................................................................................16
3.3.4 Quality of TLS ..................................................................................................................................17
3.3.5 Bentley Pointools V8i ......................................................................................................................21
3.3.6 Conversion of point cloud to CAD format .................................................................................25
4 Results of case studies ......................................................................................................................................27
4.1 Benchmarking ............................................................................................................................................27
4.1.1 Laser scanning at Volvo Cars .........................................................................................................27
4.1.2 TLS manufacturers and processing software ..............................................................................29
4.2 Case study scanning ..................................................................................................................................29
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4.2.1 Scanning locations description ......................................................................................................30
4.2.2 Scanning time study .........................................................................................................................32
4.3 Usability of the software tested...............................................................................................................33
4.3.1 Faro Scene .........................................................................................................................................33
4.3.2 Bentley Pointools V8i ......................................................................................................................36
4.4 Cost calculations ........................................................................................................................................42
4.4.1 Expenditures .....................................................................................................................................42
4.4.2 Earnings .............................................................................................................................................43
4.4.3 MIKA calculation ............................................................................................................................44
4.5 Factory Scanning Process ........................................................................................................................44
4.5.1 Perform scanning .............................................................................................................................45
4.5.2 Perform processing ..........................................................................................................................47
4.5.3 Use point cloud ................................................................................................................................49
4.6 Factory Scanning Process implemented in the Factory Design Process ..........................................50
4.6.1 Pre-study ............................................................................................................................................50
4.6.2 Project planning ...............................................................................................................................50
4.6.3 Final planning and installation .......................................................................................................50
5 Analysis and discussion ....................................................................................................................................53
5.1 Technology and applications of laser scanning ....................................................................................53
5.1.1 Technology of laser scanning .........................................................................................................53
5.1.2 Usable features of the software .....................................................................................................54
5.1.3 Conversion to CAD models ..........................................................................................................55
5.2 Cost analysis ...............................................................................................................................................55
5.3 Scanning process model analysis ............................................................................................................56
5.3.1 Factory Scanning Process ...............................................................................................................56
5.3.2 Factory Scanning Process in Factory Design Process ...............................................................56
6 Conclusion ..........................................................................................................................................................59
6.1 Result of the research questions .............................................................................................................59
6.2 Recommendations to Scania ...................................................................................................................60
7 Future work ........................................................................................................................................................63
References .....................................................................................................................................................................65
Appendix
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1 Introduction This chapter provides a background for the master thesis research and its purpose. It also involves the problem analysis,
delimitations and the outline of the thesis.
1.1 Background
Today the global market puts higher requirements on exports and more production are sent to low-wage
countries. The production and manufacturing industries requires ever-greater productivity, more savings
and less waste. The need to design and build new factories or make changes to an existing factory layout
has increased mainly because of the rapid changes in customer demand for both product quantity and
product variety. In order to remain competitive and meet market requirements, businesses need to be
more agile to plan, design and reconfigure the factory layout quickly (Chen, et al., 2012).
1.1.1 Current problems at Scania
Making mistakes or discovering errors too late in the factory layout process is very costly. The layouts
aren’t always accurate or updated and the layouts accessible by the Scania production engineers often lack
enough information of the ceiling in the buildings (Andersson, 2013).
Documents such as CAD or drawings often exist for most buildings, but these can be hard to obtain,
difficult to understand without the proper context and might be changed without a proper update. This
leads to a lot of waste in movement when employees have to go out in production to perform control
measurements and remember important details to avoid errors. Some employees even has to photograph
locations and take notes of measurements each time a new project begins, which also might be impossible
when production isn’t down (Jardemyr, 2013).
The software used to draw and develop layouts at Scania is called LayCad , a tailor made version of
AutoCad Architecture and it is mainly used by production engineers and facility engineers. In LayCad, the
layouts are often represented as top viewed 2D incision just above floor level with some equipment and
machines represented as 3D sketches. Moving parts such as doors and hatches also needs to be drawn
opened (Allard & Sättermon, 2002).
The production engineer at Scania has the responsibility to make sure that the layout, covering each
engineers responsible workshop area and common areas in the factory, is updated and representing the
current situation, which should also be controlled once a year. The engineer is also responsible for
maintaining the file structure, applying correct status of the layout file and purge obsolete files. Apart from
each production engineer’s responsibility of the personal area, a layout coordinator has an overall
responsibility of the whole production area consisting of the others’ layouts (Allard & Sättermon, 2002).
DynaMate, a subsidiary to Scania, offers technical services within production maintenance & facility
management. Their special competence includes electricity, ventilation, construction and robot
installations (Scania Inline, 2013). All construction changes of the facilities at Scania must go through
DynaMate to assure that the digital construction drawing is updated and making sure that all layout
drawings have a common building origin to enable comparisons of the drawings (Karlsson, 2013). When
the origin of the building is not marked out, entrepreneurs are hired to measure the facility. However, the
majority of the 2D and 3D digital production layouts do not include information and documentation
about the ceiling, ventilations and media installations, making it hard to gain an overview of the area
without studying the actual location in detail, on site.
Regardless of the improvements done so far, many of the LayCad users within Scania and DynaMate
experience limitations and problems concerning the layout and construction design process. Layout
drawings of the facilities could have deviations in the range of a couple of decimeters (Karlsson, 2013) and
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pillars are moved, new walls are built and other major changes are made without the digital layout being
properly updated (Mårtensson, 2012). To subsequently update the CAD files manually would imply a
major workload from control measuring the facilities.
Several of Scania's older buildings are only documented on paper drawings which have been scanned to
pdf-format and therefore cannot be imported and compared in LayCad. The actual digitalization to
LayCad of the scanned paper drawings are done stepwise when parts of the facilities are being rebuilt and
are based on the old drawings and new measurements.
The uncertainty of how the reality differs from the layouts and drawings creates many problems and
unnecessary work. A general perception of the production and facility engineers is that the layout basis
lacks of information and is inaccurate, which obliges them to control measure and collect additional data
manually using measuring tape or laser distance meters (Andersson, 2013; Johansson, 2013). Unevenness
is excluded in the layouts and in many cases cable shafts and other ditches are not represented at all.
Creating new layouts, facility constructions or installing machines therefore demands knowledge of the
actual site in order to avoid errors or problems since many details aren’t documented.
Commonly, the production engineer has to go between the office and the production floor multiple times
to measure and control the layout during a project (Andersson, 2013). The collection of measurements
may interfere with the production which might need to be stopped. The results also need to be critically
questioned and validated since the quality and accuracy of the measurement depend on the usage of the
hand held laser distance meter.
With the overall responsibility of Scania’s facility service, DynaMate needs to travel long distances
between their office and the locations needed to modify to collect information. The area is documented
with several digital photographs and the interesting measurements are noted and taken manually
(Jardemyr, 2013). This is very time consuming and it is demanding several visits when a measurement has
been overlooked or a detail have not been documented (Jardemyr, 2013). Minor mistakes made while
capturing the data lead to errors and simplified models of the reality.
The uncertainty and difficulty to verify new installations of new machines, gantry robots and equipment
due to the lack of knowledge of the ceiling of the facilities often result in clashes and delayed projects or
additional costs (Gustafsson, 2013). Having to move pillars, re-support the ceiling and rebuild walls just to
get the equipment in place is not unusual (Gustafsson, 2013).
Clashes has also occurred in production when employees been unable to verify changes before
implementation leading to costly stops in the production line (Bergman, 2013) and there is a wish from
production engineers to be able to verify new products, at the development stage, in existing production
lines and undocumented fixtures (Nordberg, 2013). This sort of request can also be found at the
aftermarket method engineers who have problems validating if new service tools will fit inside the service
stations, along with new truck models (Carlsson, et al., 2013).
1.1.2 Origin of the thesis
There is a need of new methods and tools in order to reduce stops, insecurity, waste and errors during the
development and implementation of new factory layouts and products. During the last decade the tools
and software supporting the industrial activities has developed rapidly such as CAD, CAM, digital
assembly, virtual manufacturing and other simulation tools just to mention a few.
In 2003, Scania was introduced to a method of mapping buildings and facilities in a relatively simple and
fast way with the use of 3D laser scanning. A laser scan was done at Scania Södertälje’s engine assembly
in 2004 with the purpose to test and evaluate the technique and its usability for Scania. The project was
5
cancelled, mainly because the doubts of the usability of the results and how to manage the data (Kull,
2013; Rosengren, 2013). Scania CV AB started working with Digital Factory year 2009 (Hanson, 2013), a
methodology that uses digital tools to examine and verify changes in the production or facility layout
before the implementation in the real factory.
Through networking with other automotive companies, such as Volkswagen and Volvo Cars, Scania saw
new possibilities in the laser scanning technology. During the last decade the technology of laser scanning
has developed rapidly and the tools increased beyond just measuring and being a tool for facility services.
By observing how Volvo Cars uses scanning in their business, today one of the world leading companies
within the field of industrial 3D laser scanning, Scania renewed the interest of the technology and method
which lead to this master thesis (Hanson, 2013).
1.2 Purpose
The purpose of this study was to investigate and evaluate the method and technology of 3D laser scanning
in order to find benefits and drawbacks of using the technology within manufacturing industries.
Furthermore, the study investigated how other companies use the technology today and if the
methodology is profitable in a cost perspective. Another goal of the study was to deliver a process model
of how a laser scanning can be preformed and how 3D laser scanning could be implemented in the
current work flow regarding the factory layout development process.
1.3 Problem analysis
Based on the background and purpose four research questions were formulated in order to be answered in
the thesis.
RQ1: How can the technology of laser scanning facilitate the development and maintenance of
production systems within manufacturing industries?
RQ2: How does the automotive industry use laser scanning today?
RQ3: How can laser scanning be profitable?
RQ4: How can laser scanning be implemented in the current layout work regarding the factory
design process, at Scania?
1.4 Delimitations
Several delimitations were taken in consideration in this thesis.
The scanning performed at Scania was done by external consultants, based on good credentials and
previous contact, using a Faro Focus 3D terrestrial laser scanner (TLS) and the associated registration
software Faro Scene. Other consultants and equipment with associated software are available on the
Swedish market but these have only been studied for comparative purposes. The experiences learned and
the results from the study are based on the three scans preformed at the transmission machining, axle
assembly and aftermarket service of Scania.
Volkswagen is currently using the Bentley software platform, which includes applications like Bentley
Microstation for layout design. As a part of the Volkswagen Group, Scania also sees the profit of using the
Bentley platform in the future, why the Bentley Pointools V8i was used in order to handle laser scanned
point clouds in the study. Furthermore, no plug-in software has been studied.
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2 Methodology This chapter is going to highlight the different research methods that were used during the study.
2.1 Method model of the study
This master thesis project was performed at the industrial development department, TEE, of Scania CV
AB, one of the world’s leading manufacturers of heavy trucks and buses. Other important business areas
are industrial and marine engines as well as services. The head quarter is locates in Södertälje, Sweden, and
the production is located in Sweden, France, Netherlands, Argentina, Brazil, Poland, and Russia (Scania
CV AB, 2012). In order to maintain competitive and profitable, Scania works continually to improve their
processes and methods. The master thesis was considered as a pre-study of how the factory design
process and general work of the engineer could be more efficient by using the technology of 3D laser
scanning.
Due to the specific company focus, the design of the study was a case study. A case study design is useful
when studying a process and possibilities of change (Davidsson & Patel, 2003), which was similar to the
objective of this study. The case study can gain knowledge and great depth of understanding for the key
company (Wallen, 1996) and it enables different methods of collecting data such as document study,
interviews and observation (Yin, 2008). However, a case study is usually very time consuming and it might
be difficult to finish, and it may risk to lose its general applicability if the case is too narrow (Wallen,
1996).
The current situation and previous research was studied both through primary and secondary data, i.e.
data collected in the study via interviews and contacts, or information and data collected by someone else
through articles and papers (Björklund & Paulsson, 2007). In addition to Scania, other companies
currently using laser scanning was benchmarked in order to find the best practices from other industries
(Boxwell, 1994).
Since the methods of finding output of the research questions differ depending on each question, they will
be presented individually in the following sections.
2.1.1 Finding output to RQ1
To understand the technology and background of 3D laser scanning, information has been collected
through articles, books, manuals, datasheets and interviews. In order to understand the current situation at
Scania concerning needs, problems and thoughts several qualitative and semi-structured interviews
together with seminars and demonstrations were held with production engineers, project engineers,
project managers, scanning consultants and PhD students.
Two visits have been made to the Gothenburg based company ATS AB in order to learn how to use the
two software Faro Scene and Bentley Pointools V8i for processing and editing point clouds, and thereby
find and understand usable applications.
2.1.2 Finding output to RQ2
The company chosen to be observed and benchmarked was Volvo Cars since they are considered to be
the world leading automobile company in using laser scanning to support their business (Rehn, 2011).
Their experience and recommendations gave a perception of how Scania can work with laser scanning.
To investigate how the scanning retailing market looks like in Sweden, which brands that are supported
and which processing software exist the different consulting and retailing companies ATS AB, Trimtech
and Leica Geosystems, all with sales and support of different brands, was compared.
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2.1.3 Finding output to RQ3
To get an indication whether the method of using laser scanning can be profitable and generate payoff
within a couple of years a calculation was made based on collected information of expenditures and
earnings related to scanning. The calculations were made with the help of the Scania MIKA-template,
comparing the profit of the methods of internal and external scanning. However the MIKA-calculation
should not be seen as a basis for investments.
2.1.4 Finding output to RQ4
To gain deeper knowledge of performing laser scanning and investigate how it can be implemented in the
current layout process methodology, three Scania locations were scanned. The three locations were
selected in order to include different business areas such as production and aftermarket. The production
was divided into both machine processing and assembly. These three locations were considered as three
different cases where it is possible to study how laser scanning can facilitate and support the work and
processes related to each division.
The three cases will scan and study:
Machining group processing transmission gears, building 081 in Södertälje.
Assembly line of rear axles, building 210 in Södertälje.
Aftermarket service station, Kungens Kurva.
The observations and experiences gained from these activities provided a basis of involving and
implementing laser scanning in the current factory design process methodology at Scania, using a Astrakan
process model (Astrakan, 2010).
2.2 Data collection
Depending on the available resources and the purpose, background and length of the study, different
methods can be used in order to collect data. According to Andersen (Andersen, 1994), there are three
main ways: Document studies, Interviews and Observations.
2.2.1 Document study
The purpose of the document study is to use explicit data (Andersen, 1994) such as literature, annual
reports and articles. The documents used in this study were mainly articles from journals, conference
research reports, books, PhD dissertations, webpage information, supplier manuals, lecture slides and
internal documentations at Scania.
2.2.2 Interviews
Interviews can be performed either verbally or through written surveys (Andersen, 1994). All interviews
performed for this study were verbally with follow-up questions mostly answered through written
correspondence.
Interview methods can be divided into structured, semi-structured and unstructured (Björklund &
Paulsson, 2007). For these research interviews, the method of using semi-structured interviews were
chosen in order to construct open-ended questions to allow discussion and spontaneous follow-up
questions (Jacobsen, 1993; Björklund & Paulsen, 2007). With the main focus on the individual’s work
tasks and reasoning about laser scanning, the choice of qualitative interviews was justified prior to
quantitative (Trost, 2005).
2.2.3 Observation
Observations can be performed in two ways, either participating observations or non-participating
observations, preferably in the beginning of the study (Andersen, 1994). Through observations behaviors
9
can be observed directly and the researcher is always in direct contact to the objects being observed
(Andersen, 1994).
This study included both types of observations. Non-participating observations of different production
locations to gain understanding of the current situation and participated observations of the actual laser
scanning performed at Scania and usage of the laser scan software.
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3 Theoretical framework The purpose of this chapter is to give a deeper understanding of the subject and current research. The chapter starts by briefly
describing the terms of digital factory and digital manufacturing. Next section highlights and describes the current factory
design process and a method of evaluating layout software. Further on, the chapter comprises a description of the background
and technology of 3D laser scanners with the main focus on terrestrial laser scanning. Finally the chapter introduces the
software used for editing and modeling of point clouds, Bentley Pointools V8i, with a description of its functions and claimed
usability.
3.1 Digital factories & digital manufacturing
The digitization of production has introduced two concepts that are widely used in digital simulation and
planning. These two concepts are digital factories and digital manufacturing. The modern production
world often speaks about digital factories, but any general definitions are difficult to find. The terms are
often vague and therefore companies and industries like to use and interpret the concept in their own way.
The two terms are easily mixed up because they resemble each other, and they are sometimes incorrectly
treated as synonyms, but their definitions and meanings are important to distinguish.
Digital factories concerns the technology used for capturing and representing information to model
manufacturing systems and available processes in a factory (Kjellberg, 2006). The purpose of the digital
factory is to mirror a factory and its available processes and therefore represent the relevant information
of the factory’s resources and processes. These can be tools, machine tools, fixtures, conveyors, buffer
and so on. The digital factory will also be a resource model that can be used as a base for preparation,
plant design and layout of the production as well as being a tool for layout, material flows and analyzes
(Kjellberg, 2006).
A digital factory is a model of a hypothetical or real manufacturing system, process or resource (Sivard,
2012). However, as a part of the digital factory, validation and optimization is done with digital
manufacturing which should mirror the actual manufacturing through simulation and analysis. Digital
manufacturing can therefore be defined as the technology used to process information in order to verify
and optimize the manufacturing of products (Kjellberg, 2006).
The tools and utilities available within digital factories gain a lot of advantages. Although investing in new
software and knowledge costs a lot, both financially and temporally, the profit is much larger in the long
run. Building a brand new factory or only implement or install a new machine in an existing flow is very
costly. Changes in a project are always more expensive at the end of a project than at the beginning.
Making mistakes and having to redo in retrospect must be avoided and it is important to get it right from
the start. Therefore, it is more cost effective to simulate the factory in a digital environment where
collisions, laws and regulations can be checked and modifications and optimizations be done without
affecting the existing production line in operation.
The digital way of working provides a streamlining of the entire work process including increasing product
quality, reduced "time to market" while it enables interaction between supplier networks (Sivard, 2012).
These systems provide an early verification and control of the process and a better opportunity to
optimize and evaluate the factory before it is realized.
A digital factory is also a great tool for planning and communication. A virtual model is easy to present
and explain to others, and it can provide a basis for planning and job descriptions for project members
and outside contractors. Different designs of the factory layout can be tested and evaluated as it can be
easily presented to decision makers by using data and models.
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3.2 Factory layout
This section intends to describe what a factory layout is and what functions that should be included in
factory layout software. It also describes the current factory design process, for developing and
implementing factory layout, used at Scania.
3.2.1 Layout software evaluation
In a published article by Chen et al. (2012), the authors describe the layout process and what factors and
functions that should be included and evaluated in layout software.
The objective of the layout process is to place the equipment in the best way possible so it enables an
efficient material flow for the intended volumes and product families. The layout should visualize and
confirm that the equipment fits inside a building and that the installations meets the required constraints
regarding for example space, media (ventilation, electricity, and plumbing) and laws concerning safety and
ergonomics. The layout can also be used to verify the environment for the operators working in it.
The process of developing a layout can be divided into two phases; the concept phase and the detailed
phase. In the concept phase, a block layout is created and used to show the product flow in the
production. The layout typically shows which areas that are intended for operators, machines or conveyers
and how the areas are supposed to be linked together. For example, the block layout can confirm that a
machine’s material requirements can be satisfied from a nearby truck corridor.
In the detailed layout design phase, the physical connections and models of each system are evolving to
become more detailed and exact. In this phase more detailed optimizations and simulations are done such
as interdependencies between different equipment geometry. This can result in clashes which need to be
resolved and redone in order to avoid and detect future problems. The detailed layout design is then ready
to be implemented. But before the layout can be realized, the installation of the equipment and the
constructions needs to be planned in detail to enable an efficient and safe implementation. The authors of
the article (Chen, et al., 2012) has identified and summarized requirements and functionalities of a layout
software based on industrial needs in order to enhance the effectiveness the layout process. The systems
should be able to coordinate different layouts developed by different disciplines in a collaboration
environment. It should also be possible to exchange and manage models and information from different
sources. The requirements and functions, mostly related to creation, verification and modification of
layouts, can be divided into five areas:
Creation of layouts models
Coordination of various models
Management of change and logistics
Verification of layout
Usability, efficiency and extendibility constrains
3.2.1.1 Creation of layouts models
The layout models describing the production can vary depending on the nature of the industry and what is
manufactured. Generally the layouts include block layout, building layout, machinery layout, foundation
layout and media layout (ventilation, heating, plumbing and electricity).
The layout can be represented in both 2D and 3D design or in a combination of them both. The 2D
design might be considered as an old way of working but it still has some advantages and is used in many
companies.
The 2D layout creates a good top-view were the focus of the model is on the floor layout.
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There is a well-developed archive of established drawing annunciations for measurements, doors
and coordinates which mediates the information clearly, yet to be developed in 3D.
2D layouts are easy to print out which is an advantage if one lacks digital aids.
On the other hand the 3D design layout process is more agile, since it accelerates the layout process and
provides the design team with rapid layout design and simulation. This can enhance the factory design and
construction which will shorten the time to design a new layout or reconfigure an old one.
The 3D technique is an efficient tool to use when in consideration of more dimensions of the
model, such as the height of a ceiling.
The 3D visualization makes verifications based on the human perception much simpler to detect,
such as two components being too close to each other.
3.2.1.2 Coordination of various models
Models of buildings, media, machine tools and other equipment are often created by different
stakeholders using different systems. One of the most important tasks in layout design is to consolidate
and integrate the different models into the layout. In order to accommodate this, it is essential that the
layout software can support several kinds of file formats from different system vendors without losing
geometry, data or other information.
3.2.1.3 Management of change and logistics
Design and development of a layout is a gradual process. Small changes and updates are done
continuously, resulting in many updates and different versions. At the same time many stakeholders may
be using and modifying the same layouts and models, without even knowing it. Therefore, as one
stakeholder modifies a corresponding layout or model, this will affect layouts designed by other disciplines
and it is necessary that this change is managed correctly.
In order to facilitate this process it is preferred that the system can show the files current status and
version number, e.g. draft, review, release etc., making sure that the right version of layout components
from various sources is being used.
3.2.1.4 Verification of layout
A well created layout needs to prove and verify many various aspects according to safety requirements,
legislations and specifications. The article (Chen, et al., 2012) mentions aspects and features such as:
Checking if the components will fit or collide either through viewing or automatic checking the
geometry of the model. If using automatic clash detection it is preferable to be able to set
tolerances of the collision.
Checking requirements and legislations according to safety and ergonomics based on if-condition
rules.
Working conditions through immersion.
Checking product flow and productivity.
Walk through, which is an effective way of verifying a model and gain a rapid perception of the
models potential.
The ability to set out and save notes in the model, allowing other users to easily read and gain
understanding of the model, which can facilitate communications.
3.2.1.5 Usability, efficiency and extendibility constrains
The software should be easy to use and easy to learn since production designers are typically not CAD
experts.
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Layout models are often very large when comprised by sub-models. A important functionality of layout
software in order to increase the efficiency is the ability to simplify models by deciding the size range or
scale of components that are desired to visualized. This saves computer power and disk space. However,
there must be an agreement of level of detail to avoid mistakes and in order to be more extensible.
3.2.2 Factory Design Process
The current process regarding layout development and implementation at Scania, Appendix A, is divided
into three major phases (Chen, 2010).
Pre-study
Project planning
Final planning and Installation
Each of the phases is divided to responsible units both internally and externally. The internal part refers to
the production technique units at Scania. The external part consists of machine suppliers and DynaMate,
who provide Scania with property and production maintenance and building projects.
3.2.2.1 Pre-study
When in need of changes in the production layout, e.g. a new machine, the process begins with a pre-
study. This intends to lead to a concept and a decision if the project should be realized or not. The
production engineers responsible of the specific area start with making a concept solution. This includes
Value Stream Mapping, flow diagrams and a block layout. The block layout is based on LayCad models in
DWG or DXF formats.
A request is then sent to DynaMate. They will evaluate the opportunities and the status of the current
building such as investigating the foundations, the groundwater and if any explosive entries are needed to
fulfill the requirements. The preconditions of the facility, evaluated by DynaMate, are then sent back to
the production engineers who will create a rough layout. This rough layout should consist of construction
and media documentations and shortly describe:
Number of machines
Rough electrical output
Human resources, the operator needs
Number of foundations
Number of heavy lifting
Break room / dining room / lounge with quantity
Number of office locations
Number of square meters
Process withdrawals
Cooling
Toilets
The rough layout should also be attached with a rough time table with stages and milestones. From this
request DynaMate evaluate the consequences from the building and media measures. On this basis
DynaMate delivers a cost proposal for the machine installation and the facility constructions. They also
suggest improvement of the project and add comments to the timetable. With the input from DynaMate,
the Scania production engineers receive calculation basis for the machine and facility investments.
With the rough layout and the cost calculations for machine and facility investments the work from the
pre-study is handed to higher levels for project evaluation and a decision of project funding.
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3.2.2.2 Project planning
If the project is accepted and granted funding the pre-study enter the phase project planning. The
production engineers create a requirement specification and send a request to machine suppliers. The
machine suppliers then send back an offer and solution based on the requirements. Based on the different
supplier solutions the production engineers develop different alternative layouts. The layout considered as
the “best guess” is further developed into a preliminary detailed layout.
Mechanical installations, media and construction are added to the detailed layout which forms the basis
for an updated requirement specification of the facility and results in a media layout. Based on the
requirement specification of the facility DynaMate develop a detailed project plan. As a final step in the
project planning phase the production engineers starts the procurement with the chosen supplier.
3.2.2.3 Final planning and Installation
After the procurement is complete the supplier starts building the new machine. DynaMate starts their
own procurements with contractors and develop and provide construction documents for the
reconstruction. With the input from the machine supplier and DynaMate the Scania production engineers
enters the last phase. The layout is now “frozen”, i.e. considered as a final detailed layout which will not be
reconfigurable. With the final planning complete the new machine can be delivered and installed
according to the layout. As a last step in the final phase the layout is updated after the installation. This
final layout is now considered as the current state.
3.3 3D laser scanning
Today laser scanning is applicable within many fields and laser scanners exist in many different shapes and
sizes for different applications, although the basic technology often is the same. This section presents the
history of laser scanning and technology with the main focus of terrestrial laser scanning, TLS.
3.3.1 History and background
Lasers in land and engineering surveying instruments has been widely used for the last 30 years as
common parts in standard surveying instrument such as total stations, laser rangefinders, profilers, level
and alignment devices (Shan & Toth, 2009). A natural development has been to add a scanning
mechanism to a total station that were already equipped with laser rangefinders and angular encoders.
Instead of measuring very specific individual points the laser scanner would allow the automated
measurement and location of thousands of nonspecific points in the areas surrounding the position where
the laser scanner instrument has been set up, resulting in a spherical point cloud with high accuracy in a
few minutes (Shan & Toth, 2009).
According to Staiger (2011) the first laser scanners, as we know them today, appeared on the market in the
mid to late 1990’s. Since then the market has seen dramatic improvements in terms of measurement
speed, accuracy and general usability. At the same time all system became smaller, easier to handle and less
expensive. Some of the first real applications was to scan dangerous environments with limited access
such as nuclear power plants and offshore oil rigs and these industries were the main impetus for further
development (Kull, 2013).
3.3.2 Terrestrial laser scanner
Terrestrial Laser Scanning (TLS) or Light Detection And Ranging (LiDAR) systems uses lasers to make
measurements from a tripod or other stationary mount, a mobile surface vehicle, or an aircraft. The term
LiDAR is sometimes used as a synonym to laser scanning but is more often associated with the airborne
methods (Caltrans, 2011).
The stationary systems refer to laser scanning that is preformed from a static vantage point. Terrestrial
laser scanners were initially a very expensive and costly technology but have now begun to expand
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significantly for 3D measurements of structures. The technology has been used by civil engineer,
landscape and architecture applications and projects for quite some time and a major reason for its success
is that companies have realized that they, with the help of this technology, could have their facilities
plotted in real size to a relative low cost (Bosché, 2012).
There are many benefits of working with laser scanning relatively traditional methods i.e. total stations,
laser rangefinders or tape measure. These traditional methods usually takes time to do manually and they
are often in need of proper planning to avoid future supplement. The scanner can output high resolute
models of areas or objects that can be monitored easily. On the other hand the technique has some
limitations. The quality of the models obtained from a scanner is relative to the file size of the data and it
can take a significant time to complete a full scan. The systems collect a massive amount of raw data by
determining the distance from the laser source and the horizontal and the vertical angles of the laser beam
(Burton, 2007). A data point’s position can then be defined in space with a specific x, y and z coordinate.
The point also receives a laser return intensity value and, if equipped with a digital camera, a RGB color
code. The raw data product of a laser scan survey is then called a point cloud (Caltrans, 2011).
The scanner can only capture data from objects in front of it, so in order to re-create a complete 3D-
model of an object, multiple scans has to be taken from different angles. The scans are then merged
together to a joint point cloud.
3.3.3 TLS technology
Terrestrial laser scanners are classified in two different ways, the technique of measuring the distance and
the type of beam deflection system (Staiger, 2011).
3.3.3.1 Distance measuring technique
The laser scanner uses a phase based method or a pulse based method of determine the distance to the
object without an artificial reflector.
Time-of-flight systems use a focused pulse of laser light and wait for it to return to a sensor. The time it
takes for the light to return, multiplied by the speed of light in air results in how far the pulse traveled.
Since the pulse makes a round-trip, back and forth from the scanner to the object, the distance is divided
by two (Curless, 1999). The accuracy of a time-of-flight system is therefore depending on how precise the
scanner can measure the time since the light travel approximately 1 mm in 3,3 picoseconds.
In phase-based measurement technology, the laser scanner transmits an amplitude-modulated continuous-
wave laser beam. The target distance is proportional to the phase difference and the wave length of the
amplitude-modulated signal (Akin, et al., 2008). By using phase-shift algorithms the laser scanner
determine the distance based on the unique properties of each individual phase by computing the phase
difference between the emitted and reflected power signals (Curless, 1999), where the reflected power is
provided by the amplitude of the reflected beam (Akin, et al., 2008).
The two described measuring techniques are illustrated in Figure 1.
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Figure 1. Working principle of phase-based and time-of-flight (pulse-based) laser scanners (Akin, et al., 2008).
The pulse based system assures a wide measurement range but are slower than a phase based instrument.
Vice versa, the phase based techniques allows a high measurement frequency but are limited in the range.
Although, the difference between the two methods are becoming smaller with the latest generation of
laser scanners (Staiger, 2011).
3.3.3.2 Type of beam deflection
Laser scanner can be divided into three types of different beam deflection system (Staiger, 2011). These
types are camera-, hybrid- and panorama-scanners, which can be seen in Figure 2. The panorama type has
the biggest Field-of-View (FOV) which is especially useful for indoor situations, and today the most
common type on the market.
Figure 2. Classification of TLS by the type of beam deflection system (Staiger, 2011).
3.3.4 Quality of TLS
The result and quality from a scan is dependent on several factors. Staiger (2005) identified and
summarized several parameters influencing the geometrical quality of the scans, Table 1.
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Table 1. The parameters that can affect the scan result according to Staiger (2005).
3.3.4.1 Materials, accuracy & range
The accuracy of the measurements captured by the scanner is dependent on the angle of incidence to the
surface. Measurements taken from a surface that are perpendicular to the laser beam will produce better
accuracies than those with a large angle of indigence to the surface. This may produce errors in the
distance returned since the beam can elongate more with a larger angle (Caltrans, 2011).
Systematic test series have proven that different materials of the scanned object may have significant
influences on the measurements of TLS, especially building materials such as concrete and metal plates
(Voegtle & Wakaluk, 2009). The research performed by Voegtl and Wakaluk (2009) has shown that the
range correction value increases with longer distances (nonlinear) and lower reflectivity of surface material.
The standard deviation of range measurements also increased with longer distances, with about a factor of
two, and reduced reflectivity. The intensity value were rather constant for different ranges but decreased
with wider incidence angles and the standard deviation of intensity increased with higher reflectivity
(Voegtle & Wakaluk, 2009).
A short comparison of the accuracy, working range and measurement rate of three of the most common
laser scanners most suitable for industrial indoor application is listed in Table 2.
Table 2. Comparison of accuracy, range and measurement rate (Faro, 2013; Trimble, 2013; Leica Geosystems, 2013)
3.3.4.2 Referencing targets and merging scans
Objects or areas being scanned are often quite large and complex in shape. Therefore several different
setups of the laser scanner should be made in order to capture the object completely from all necessary
viewpoints (Reshetyuk, 2009). In order to obtain a complete representation of the scanned object or area,
the scans should be transformed to a merged point cloud with a common coordinate system (Reshetyuk,
2009). Normally, the scanning is performed in such a way that the scans overlap pair wise. This means that
a point cloud overlaps with the point cloud captured from the next scanner setup, see Figure 3.
Parameters affecting the scans
Object
• Size
• Curvature
• Orientation
• Surface
Scanner
• Performace of angels
• Performance of distance
• Calibartion
• Synchronisation
Enviroment
• Vibration
• Refraction
• Optical Perturbations
Method of data acquisition
• Point density
• Number and position of reference points
• Postion & number of scans
• Distance from the object
Method of calculation
• Target Recognition
• Registration
• Calculation of elements
Brand Accuracy Range Measurement rate
FARO (Focus 3D) ± 2 mm 0.6 – 120m 976,000 points/sec
Trimble (Tx5) ± 2 mm (10-25m) 0.6 – 120m 976,000 points/sec
Leica (P20) ± 3 mm (50m) 0.1 – 120m 1,000,000 pints/sec
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Figure 3. Illustration of the overlapping area when register to scans (Reshetyuk, 2009).
If single scans from different observation stations have to be merged together or transformed to a
common coordinate system, it is possible to use some kind of referencing system of recognizable targets
(Boehler & Marbs, 2002). It is desirable that these targets can be easily and accurately detectable by the
scan registration software, such as spheres or plane target (Boehler & Marbs, 2002), Figure 4.
Figure 4. Spherical target.
Unlike the flat targets, spherical targets can be reduced to a single point in the center of the sphere and
they can easily be identified from any scanning direction (Reshetyuk, 2009). By placing the targets in the
overlapping are between two scans the registration software will be able to merge the two scans together
as illustrated in Figure 5.
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Figure 5. Registration using targets (Reshetyuk, 2009).
To obtain sufficient information from the references and to fixate the scan in space the scanner needs to
have at least 3 references in sight of every scanning position, Figure 6.
Figure 6. Example of scanning location setup, using references (Simplebim, 2013).
If necessary, it is also possible to use distinct natural point features, such as edges or corners of doors or
windows, visible in the scanned point cloud to be registered (Reshetyuk, 2009). Although some of the
accuracy of the merged scans might be lost in comparison with the spheres (Berlin, 2013).
If the area or object of interest has a known external coordinate system, e.g. from a 2D drawing or layout,
it is often wanted to transform the point cloud from the local scanner coordinate system to the external
coordinate system (Reshetyuk, 2009), described in Figure 7. The most commonly used method is to make
use of targets with known coordinates in the external system to transform the point cloud. By using a total
station, the target can be measured relative a known point. With the known x, y and z coordinates of three
targets it is possible to accurately orient and fixate scan in both position and rotation (Berlin, 2013).
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Figure 7. External and scanner coordinate system (Reshetyuk, 2009).
ATS sells a kit with their own referencing system containing several spheres and the magnets. The
magnets are possible to attach permanently by screwing them on for example concrete walls, pillars or
steel objects. By having the magnet itself fixed it is possible to rescan an area of interest retrospectively
and reuse the same reference positions. Since the references are at the same place as the old scan the new,
updated, scan can be merged into to old point cloud with the same accuracy as the first scanning session
(Berlin, 2013).
3.3.5 Bentley Pointools V8i
The Bentley Pointools V8i is a stand-alone pre-processing software for point clouds enabling 3D
visualization and editing. The software is developed to be user-friendly and allow quick processing of
point clouds and it is specially designed to handle larger point clouds, containing large amount of data
(Bentley, 2013).
3.3.5.1 System requirements
To be able to use and run the software smoothly, the system hardware has to meet certain recommended
requirements, Figure 8.
Figure 8. Bently Pointools V8i system requirements.
To fully support Bentley Pointools V8i functionality the graphics card must support OpenGL 2.0 or a
later version. This should be supported on all ATI (AMD) and NVidia Graphics hardware since 2004 but
may require a driver update. It is recommended to keep the installation of the software up to date by
downloading the latest updates from Bentley’s website since they listen to the users and release regular
updates and fixes.
Bentley pointools V8i
•Windows 8 or Windows 7
• Intel i7 or equivalent AMD quad-core processor, 2.6GHz or higher
•8GB RAM
•NVidia or ATI (AMD) graphics card with 512MB on-board memory
•200MB free disk space for installation
•1920x1080 display resolution with true colour
•3 Button mouse
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3.3.5.2 Using the software
Bentley Pointools uses its own native point cloud format POD (Point Database) that enables rapid
background loading and compact file size through compression. A POD file does not require write-access,
so it is possible to importing and displaying files from read-only media, read-only locations or shared files.
The first time a POD file is loaded it will cache, which can take from few seconds to a few minutes
depending on file size. After the file is cached subsequent loading will be instant.
The Graphical User Interface (GUI) has been designed to be as simple to use as possible and offers some
ability to customize the layout to suit the user. The software uses a ribbon style toolbar that runs along the
top of the window which makes finding the tools much faster by grouping families of tools together.
3.3.5.3 Import of different object types
Bentley Pointools V8i can import (or attach) the following types of object:
Point Clouds
3D Models
Drawings
Point Clouds
A point cloud consists of a large number of points in space that describe an object. Each point in the
cloud has a x, y, z coordinate and may also have additional properties such as color, reflective intensity or
surface normal. The software can handle billions of points with modest hardware requirements since it is
optimized for the display of point clouds.
The point cloud data can be imported from various file types from several laser scanner suppliers such as
Faro, Topcon, Leica, Riegl, Optech, Trimble and Zoller-Fröhlich. However, the files are always saved in
Bentley Pointools native file format POD to enable rapid background loading and compact file sizes.
3D Models
Textured 3D Models complete with material properties and transparency can be imported from a number
of common model formats. However, there are currently a number of import and display limitations.
Only UV, Planar and Box texture mapping modes are supported and NURBS or Sub patch / division
surfaces are not supported.
Drawings
Most drawing primitives are supported. This includes lines, arcs, circles, text and dimensions. Bentley
Pointools is able to import and display layered CAD drawing files and supports formats such as AutoCad
DXF and DWG, and there is no need to explode blocks before import.
3.3.5.4 Project files, PTL
Pointools stores the current project settings, layers, saved views, tool states and animations setups etc. in
PTL project files. For large object types such as drawing, 3D models and point clouds the PTL file creates
a reference in form of a file-path to the object which is stored rather than the data itself, in the original
file. This allows many projects to build around the same set of data without replicating the object data.
The software also features an auto-save function. Once a PTL is saved Pointools will automatically create
backup files in the same folder at regular intervals of 10 minutes. The system will auto-save up to nine
individual files before it starts to continuously overwrite the oldest backup, meaning that up to 90 minutes
of work can be traced.
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The results of point cloud editing operations are not saved back to the original POD files. This ensures
that the workflow is non-destructive, since the point cloud usually represents captured data and this is
usually the desired behavior in most industries.
3.3.5.5 Object tree
Objects in the workspace are managed in an object tree. All objects in the current project are represented
such as overall point clouds information, individual point clouds with cloud information, notes database,
drawing database with drawing layers, 3D Models database with 3D Model parts and 3D model materials.
The object tree also gives the possibility to change the visibility of each object within the current project.
3.3.5.6 Navigation
The software enables two types of viewing projection; orthographic and perspective. It also enables two types
of navigation; examine and explore. In Examine mode the viewer is rotated around the view target. In this
mode the scene rotates relative to the camera. In the Explore mode the camera is rotated instead of the
scene itself. This gives the feeling of first-person walking or flying through the environment.
The user is able to view the point cloud in RGB or intensity. Another possibility is to set the color ramp
used to display the intensity values e.g. HUE. The user can save viewpoints, save rendered snapshots and
as an extra effect view the point cloud in stereoscopic viewing (using 3D glasses).
3.3.5.7 Clipbox
Pointools features an editable clipbox tool. When viewing larger or complex point clouds it can be helpful
to use this tool to isolate an area or volume of interest.
3.3.5.8 Notes
Pointools has the ability to store and display user created information in form of notes. A note can be
attached to any point of a POD file, the end point of lines or corners of a 3D face and then be saved in
the PTL project file. Once created, the note will be visible in the viewport and can contain text
information and also a hyperlink to a web URL, a file, a saved view or an animation path. This function is
ideal for presentations since it allows the user to attach documents, images, movies and other multimedia
content to geographical locations in the point cloud.
3.3.5.9 Point editing
The software features a collection of tools for editing point cloud data for segmentation, clean up and
color correction. A RGB painting tool let the user colorize or highlight areas or objects in the point cloud
with any transparency. There is a set of tools that enables selection of part of the point cloud data were
the selected area is highlighted. The selected highlighted areas can then be hidden from view using point
visibility settings. This does not however delete the data or affect the original POD file, but enables
selected areas to be isolated and exported as separate POD files. The selected point may also be moved
between one of a possible 128 layers to isolate areas for detailed editing or for point cloud segmentation.
3.3.5.10 Layers
To enhance point cloud editing and workflow, Bentley Pointools V8i specializes the layer concept. All
layer operations are saved in the PTL project file. Users of CAD software or design authoring software
will probably be familiar with the general concept of layer based workflow.
3.3.5.11 Point transform
The transform features allows the user to use tools for selecting, moving, rotating and duplicating object.
Any operations carried out in using the transform tools do not affect the source files which the objects in
the project represents, it will just read the information stored in the project file and performs the necessary
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transformation, without really alter the values in the POD file. To make the changes permanent the file
has to be re-exported as a new file.
3.3.5.12 Taking measurements
Measurements can be taken in two ways in the point cloud and the result is saved in the PTL project file.
The measurement can either be taken by a single point position (point measure) which will show the
selected points coordinate in the viewport. The other option is to a point to point measurement (distance
measure) which will show the two points selected and the distance between them in the viewport.
The user will be able to:
Rename measurement
Add comments
Set the numerical precision of the shown output
Save the output measurements to a delimited ascii file which is a common format that can be read
by most spreadsheets and databases.
Filter out coordinate values from the second point (dx, dy, dz). Useful to make simple
measurements in only one direction.
3.3.5.13 Animation system
The Bentley Pointools V8i animation system is based on interpolation between selected keys placed on a
timeline. The timeline is divided in frames but instead of setting up each frame it is possible to set up two
or more key frames and the frames in-between are interpolated to produce a smooth motion. The
technique is referred to as Key Framing. The basis of key frame animation is that the system interpolates
between two keys to produce a smooth animation of the parameter value, which is any value that can be
animated. In fact keys represent the value of a parameter at a particular frame.
The Graph Editor enables fine tuning of Keyframe position, value and interpolation method. The editor
displays the changing value of the current selected parameter over the time as a graph with keys shown as
nodes along the graph which can be adjusted. This means that it is possible to edit a objects coordinates
relative a chosen camera position at a certain key frame on the timeline. It is also possible to parent one
object to another object. The change of any parameters that belong to the parent will also affect the child
object.
3.3.5.14 Clash detection and differencing
Bentley Pointools V8i has a toolset to test for clashes and differences. The clash detection will identify and
report any interference between any two (or more) objects. The clash detection tools contain four types of
test:
Static Interference
Dynamic Interference
Discrete Path Interference
Continuous Path Interference
This gives the ability to do one static test of an object, allow the user to move the object and see the
clashes when they occur or test the clashes during a pre-set path at any given time or along the whole
path.
The differencing tool examines two objects and highlights any differences found, either subtractions or
additions.
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3.3.6 Conversion of point cloud to CAD format
An existing method to convert point clouds to 3D models is through triangulation of the point cloud,
where an approximated mesh between the points in the cloud creates a surface. However, no conversion
procedures can recreate a surface from a point cloud flawlessly since the only information in the cloud is
the points’ coordinates without any specific relation to each other and no guarantees exist of a point cloud
completely free from disturbances (Mole & Araujo, 2010).
There are different methods to recreate surfaces, with various result and accuracy (Barbero & Ureta,
2011). In a report, Mumester and Thor (2012) evaluate software designed to triangulate pipes in industrial
environments. Their conclusion is that the method is time consuming, results in large files and most of the
accuracy from the point cloud is lost (Murmester & Thor, 2012). Similar tests have been performed where
the software can decrease the size of the files, but the method is more or less manual and involves
extracting areas that are supposed to be flat or regular (Kvist & Persson, 2010).
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4 Results of case studies This chapter will present the results of the case studies made during the master thesis. It will present benchmarking of another
company’s strategies and the market of retailers and manufacturers, currently active in Sweden, with associated processing
software. Next section will describe the locations and a time study from the case study scanning followed by usability testing of
the two software Faro Scene and Bentley Pointools V8i. The chapter will also present cost calculations containing costs of
laser scanning and a Scania payback calculation, MIKA. Finally this chapter will present the result of a methodology of
working with scanning at Scania, Factory Scanning Process, and how it could be implemented in the Factory Design Process.
4.1 Benchmarking
To get an enhanced understanding of laser scanning in the automotive industry and the retailer and
software market in general a benchmarking study are made. The automotive company that is studied is
Volvo Cars. Similar to Scania, Volvo has their headquarters in Sweden and are at the cutting edge when it
comes to using and developing laser scanning in the automotive industry. This background makes Volvo
an interesting benchmarking case of how laser scanning is used in their business.
The laser scanning retail market in Sweden represents three brands of laser scanner equipment. These
three are Faro, Trimble and Leica Geosystems. The benchmarking study is focusing on the retailers
services and a comparison of the registration software provided for each laser scanner brand.
4.1.1 Laser scanning at Volvo Cars
According to Rönnäng (2013), Volvo defines virtual manufacturing as a technology and way of working to
verify production systems virtually. This includes 2D and 3D software as well as PLM and laser scanning.
With many years of experience, Rönnäng is one of the most qualified persons with knowledge and
knowhow of laser scanning at Volvo.
Volvo Cars first came in contact with laser scanning somewhere between 1996-97. At the time, the focus
was to scan single robot cells and compare the scans to layout drawings in order to verify the layouts. In
2009 they realized that the technology had matured and developed, mainly on the software side. The main
reason of this new venture was that they could get a complete factory model from the combined scans in
color and the software could handle larger point clouds, in the range up to 10.000 m2. This improved both
the visual scope and handling of the point cloud (Rönnäng, 2013).
Today Volvo Cars is one of the world leading companies of laser scanning in the vehicle industry both
when it comes to operation and development. According to Rönnäng (2013), larger manufacturers such as
Toyota, Mercedes and Ford are trying to implement scanning in their companies but they are facing
difficulties and turns to Volvo for support and coaching. The others main focus is to scan robot cells but
their purpose of scanning is rather different. As an example, Ford’s purpose is to save money in form of
airline tickets and the availability of their engineers. Since they can analyze a production site remote
through scanning, the engineers won’t have to spend valuable time and money on traveling.
Volvo Cars are continuously faced with a large amount of new and ongoing projects. In their business
they have short time-to-market and they are working on several new car models simultaneously, produced
in the same assembly line. Testing new car models were usually done with cardboard profiles being moved
through the assembly line on Sundays when production is down and they have had problems with
verification of new cars. Almost every new model being assembled have crashed in manufacturing line
with the result of a scrap chassis, and worst of all, stop in production since they assemble all different
models in the same line (Rönnäng, 2013).
The board was persuaded and realized that the laser scanning technology could profit the company
through more exact models of their factories with high accuracy. They gained a god visualization tool as a
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discussion base for communication and a tool for simulation and verification of products and processes
digitally. Continued efforts were motivated by strategic investments of the company’s methodology
processes. Today’s users are mostly simulation- and planning engineers and maintenance engineers. There
are currently about 50 employees using the laser scan result in their daily work and 3 are working with
development. However, they estimate that about 300 would benefit from working with the results and a
vision is that everybody would have access to and a majority be working with the scanning results in 2017.
Volvo Cars are currently using several different software, such as:
Bentley Pointools V8i
Faro Scene
Faro Web-share
IPS (Industrial Path Solutions)
Process Simulate (Siemens PLM)
The actual scanning is performed by an external consultant company, ATS AB in Gothenburg. Volvo
estimates that they will run the scanning internally by themselves somewhere in 2014, focusing on local
rescans. The major global update, when rescanning the complete factory, approximately every 2-3 years,
will however probably be scanned by consultants because of the time consumption. The scans are
performed at the functional areas, covering the lines and the logistics. About 60% of their factories have
been scanned, the final assembly remains and they have just started in their new factories in China.
The laser scans produce a lot of data, in the order of Terra Byte. Large data files generates loading times
and rescans may create information conflicts. Today, Volvo Cars handles the massive amount of data with
a file structure at their intranet. Although, they have a dialogue with Siemens about a PLM system that
supports the management of scan data and files. When scanning, Volvo takes the factory and building
origin in consideration which they have also measured with a total station for higher accuracy, since when
placing a new machine, the machine origin is as important as the buildings. When using measured
reference points form the total station the experienced final scan results have accuracies around ± 3 mm,
sometimes better.
Volvo doesn’t believe that scanning will replace 2D layouts completely. They will continue to scan the
existing business and use CAD when building something new. There has been great interest of the
technology within the company, especially when showing the visual results. However, there are problems
finding owners of the technology and the data produced.
Rönnäng (2013) states that the point cloud can be used to verify the layouts according to the reality, which
would decrease the risk of making wrong decisions based on out of date layouts or distorted perception of
reality.
Positive experiences
o 3D model of reality
o Great visual tool for communication
o Verify layouts
o Simulation and validation of new products
o Decreased travel costs – higher engineer availability
o Generally positive reception of the technology
Negative experiences
o Large data files – disk space demanding
o File structure – no available PLM solutions
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o Update of point cloud
Future work
o How to save and structure the data?
o Many stakeholders but who is the owner of the data?
o Who should make the future scans internally?
4.1.2 TLS manufacturers and processing software
In order to smoothly handle data obtained from a laser scanner, the raw data has to be processed and
registered. Many of the TLS manufacturers have developed their own software compatible with their own
scanner. The main function of these software products is to process and merge the scans into a joint point
cloud. But, since the processing of the scan data is computer consuming the software are not that
optimized for modeling and further work except for viewing and measuring.
Three of the manufacturers of terrestrial 3D scanners with sales and support currently established in
Sweden are Leica Geosystems, Trimble and Faro, Table 3 .
Table 3. TLS of different brands (Trimble, 2013; Faro, 2013; Leica, 2013).
Brand Trimble Faro Leica
Scanner model TX 5 Focus 3D P20
Picture
Associated software Trimble RealWorks Faro SCENE Leica Geosystems HDS Cyclone
Leica Geosystems provide different kinds of system for measuring. The company is a part of the Swedish
company Hexagon AB, and has five sales and support offices in Sweden and headquarters in Switzerland
(Leica, 2013). Besides selling, leasing and renting scanners the company also offers service and support.
One of the Trimble authorized distributors is Trimtec AB (Trimtec, 2013). Trimtec are established in six
locations in Sweden, working with sales, support, service and training. In Sweden, Faro is represented by
the Gothenburg based company ATS AB. They offer sales, training, support, software and accessories for
the Faro Focus 3D as well as consulting projects and solutions (ATS, 2013).
The software Faro SCENE, Leica Geosystems HDS Cyclone and Trimble RealWorks are all able to
process and register raw data into a merged point cloud, file formats able to be opened in Bentley
Pointools V8i (Bentley, 2013). If making a brief comparison of the available software, based on the
functions claimed to be supported by each manufacturer, shows that the basic processing functions of the
software are rather similar. However, the Trimble and Leica software are built up by modules the can be
purchased to create an overall solution, making them able to do tasks similar to Bentley Pointools V8i.
4.2 Case study scanning
In order to be able to show the benefits of using laser scanning as a method at Scania three locations were
scanned in order to use the Scania locations in the software. With the purpose of investigating how laser
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scanning can be used in different areas within the company. In this section the three locations are
described and a time study is presented in order to give an indication of how time consuming this
technology is.
4.2.1 Scanning locations description
The locations were chosen in order to represent different business areas, both from machining, assembly
and aftermarket services. The objects that were scanned was one service station for coaches, one assembly
line for rear axles and one machine group producing transmission gears.
4.2.1.1 Service station The first scan was made at a service and maintenance station for trucks and buses. The purpose of
scanning this kind of facility is to use the point cloud to examine the space surrounding the truck or bus
when being serviced. The wish is to be able to verify new service tools and vehicle models in the point
cloud and thus facilitate for the service personnel.
The particular workshop being scanned, used for buses, consists of approximately 600 m2 of floor
relatively free from grounded objects, Figure 9. The area can support six coaches and contains a service pit
and several heavy duty hydraulic lifters, tool cabinets and other service equipment. In addition to the
equipment two busses were currently parked inside during the scans.
Figure 9. Service workshop.
4.2.1.2 Assembly line
The second scan was done in Scania building 210 in Södertälje. The scanned area can be divided in two
separate cases were one is the actual rear axle assembly line and the other a open area which had just been
emptied to make space for the differential gear assembly lines.
The open new area measure about 900 m2, fenced and framed by tarpaulin, Figure 10.
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Figure 10. Open area.
The scan of this area are made in order to find out if the laser scanner can be used as a new tool for
checking the evenness of the floor, instead of using total stations, and then try to insert a 3D model of the
new line with its machines.
The 85m long assembly line covers about 750 m2 and is crowded with assembly tools, racks and pallets
with material, a robot cell and has about 30 visible carriers carrying heavy duty truck axles. The huge
amount of objects, Figure 11, made it into an interesting case with the purpose to see if the laser scanning
technology enables the verification of new 3D CAD products in an existing assembly flow.
Figure 11. Rear axle assembly line.
4.2.1.3 Machine group
The last scanning was performed in building 081 in Södertälje, which produces transmission gears. The
main focus of this scan was a certain machine group consisting of several machine tools, two robot cells,
conveyers and a Megamat Megalift tool magazine, covering about 600 m2. The area has several confined
spaces since most of the equipment is placed closed to each other and close to the truck corridor making
it hard to plan installations of new machines, Figure 12.
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Figure 12. Machine group.
One of the existing machines are planned to be replaced and the production engineers are aware that their
layout drawings are inaccurate concerning walls and pillars in the building. The purpose of this scan is to
verify the existing layout drawings with the scanned result and replace the old machine with the new 3D
model and try to simulate the installation.
4.2.2 Scanning time study
In order to get a comprehension of how time consuming the scanning process is the times of each scan
location were recorded. The result of the time study is summarized in Table 4 in order to give an
estimation of how time consuming the laser scanning can be at different locations and business areas of
Scania.
Table 4. Summarized time study of scanned locations.
Scanning locations Transmission Gear Machine Group (By081)
Service Workshop (Kungens
Kurva)
Rear Axle Assembly Line
(By210)
Open Area (By210)
Business Area Machining After Market Assembly Assembly / Facility Service
Scanned area 600 m2 550 m2 750 m2 900 m2
Amount of objects Medium Medium High Non
Planning time 40 min 40 min 30 min 10 min
No of scans 16 17 19 4
Time/scan (quality) 7,5 min (high) 7,5 min (medium)
5 min (medium) 7,5 min (high)
Scan time 3 h 3 h 2 h 30 min 30 min
Area per scan hour ~ 200 m2/h ~ 180 m2/h ~ 300 m2/h ~ 1800 m2/h
Overall Total time ~ 3h 40min ~ 3h 40min ~ 3 h ~ 40 min
Processing of clouds ~1 h ~1 h ~ 1 h ~ 30 min
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4.3 Usability of the software tested
The results of the testing of the software are based on usability at the locations scanned in the case study.
4.3.1 Faro Scene
The Faro Scene software is a usable tool when validating and processing the raw scan data, captured from
the laser scanner, in order to merge the scan positions together to a point cloud. It is possible to view each
scan position as an intensity or color panorama photo, quick view or a 3D view of the scanned area. The
3D view, however, requires a lot of computer power.
The registration can be done automatically and the references spheres are found when the program goes
through all scans, creating spheres based on the radius of the objects in the scan. The automatic
registration of spheres may however find objects with shapes similar to the reference spheres, Figure 13,
which may lead to errors in the merged point cloud.
Figure 13. Error in automatic registration of reference spheres.
The automatic registration of the references gives each found sphere an identification number and tries to
find the same sphere in another scan in order to merge the two scans together. This can create errors
when the software incorrectly identifies two spheres from different scans as the same and merges the two
scans together. If not discovered, this will result in a corrupt and disfigured point cloud, Figure 14.
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Figure 14. Wrongly merged point cloud (red) in rear axle assembly.
When the scan points are merged together and can be chosen to view as a complete point cloud, it can be
used for measuring between points. The user can also create planes from surfaces which can be measured
from. These planes are generated by the software as an average of the points within the user selected area.
Another usable application in the Faro Scene software is the possibility of creating web-accessible
material. This allows the scan data from the project to be shared with others over the internet and does
not require knowledge about laser scanning or 3D systems, with no risk to ruin the material from the
scans. Much alike modern online map services with “street view” functions the Faro Scene Webshare can
represent each scan position as a panoramic view. The scans are also represented in a joint overview map
and in an album containing all the scans. Measurements can be taken in 3D in the panoramic view and in
2D distances and areas in the overview map.
Notes can be added to any point in the scanned panoramic view making it possible to add descriptions
and/or hyperlinks to objects. The software does however not recognize an object automatically.
The mentioned functions can be seen in Figure 15.
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Figure 15. Interface of Faro Scene Webshare.
However, the user must be careful when measuring in the panorama view, since the web viewer does not
support to view the measurement in 3D and therefore doesn’t give the user the opportunity to verify the
selected point’s position in three dimensions and different views. If measuring the width of an object in
front of a wall the user will try to measure from side-to-side of the object as close to the edges as possible.
Even if the measured point seems to be at the right position, at the edge of the object, it may have been
placed wrongly on the wall behind the object. It may look correct but if not noticed it will provide a
wrong basis to the user.
The user has the option to switch between standard and high resolution (HD) of the panorama view
quality. The HD function clarifies the view significantly, at the expense of internet browser buffer times.
Another useful tool is the color and intensity option. This allows the user to change the viewed scan in
color or the laser intensity as a gray scale, which instantly can improve the comprehension of the scene
viewed. As the scanner uses a digital camera to capture the color of the scanned area it automatically
adjusts the aperture and the shutter speed. In scenes with different lightning settings this may result in
dark areas, e.g. behind lights or areas far away from the scanner. In the scanned factories this was shown
most clearly in the ceiling, Figure 16.
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Figure 16. Comparison of viewing RGB or Intensity.
4.3.2 Bentley Pointools V8i
The overall impression of using Bentley Pointools V8i is good. Even as a new user it is easy to orient
because of the user friendly interface. The featured functions seem logical and pedagogical. The
navigation, using Examine or Explore, may at first seem difficult and a bit different from common CAD
software but it is easy to get used to.
Pointools V8i is able to import many different file formats used in common Scania-used software such as
LayCad, Catia and Delmia. The import of files may take some loading time since the POD files usually are
quite large, around 1 GB, and the data need to cache the first time opened. The large file sizes of the point
clouds and models require a powerful computer in order to have the software run smooth.
The export from Bentley works quite irregularly and the exportable file formats are rather few. Converting
3D models, e.g. from Catia formats or Step format, into POD files usually work without any problems,
although, the POD file demands multiple disk space compared to the original file. When exporting
selected parts of the point cloud to be used by other CAD software, mainly in DXF format, the software
require lots of time and it often fails and crashes. This showing that this method of exporting point clouds
from Pointools to other software, is not useable enough yet and need to mature unless the CAD software
are able to import the POD format.
One of the major advantages concerning Pointools is its ability to open, view and compare different file
formats at the same time. This is useful since it enables the user to compare e.g. an layout created in
LayCad with 3D-models created in Catia, at the same time as both can be analyzed in comparison with the
point cloud. This is especially useful when the imported objects have the same origin. To be able to use
the imported files most efficiently, they should be converted to POD-files which is fairly simple and quick,
since that is the original file format designed for the software. However, when importing files to
Pointools, you have to analyze the result since the information from the imported and converted files
might be lost. The models may therefore look corrupt when files containing file-paths may lose its
relations to other files which are not imported.
The user should also notice that models built up by different parts will be represented as a rigid object
when converted to a point cloud, POD file, with no possibility to move individual parts. The user should
also be aware of layout files loosing sketched lines as well as 3D models loosing geometries or details.
Another discovered disadvantage concerning the file import management is that Pointools have problems
opening files currently used by another software, such as LayCad. In this case, LayCad must be shut down
in order to allow the file to be imported into Pointools.
Pointools is an editing and validation software. Since it is not designed to be a layout program it does not
allow the user to draw any new layouts or sketches. Nor is it an engineering CAD software where the user
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can create and design new 3D models. Therefore no further modifications, other than point cloud editing,
are possible regarding imported files. Additional modifications have to be done in other software and then
imported.
The use of PTL files works well, as modifications are only made relatively the original files which do not
risk destroying the basic data. The same applies to the work of layers which makes it easy to split the
information in the point cloud if needed, without affecting the original file. This also makes it possible for
multiple users to use and exploit the same basic data simultaneously.
The object tree in Pointools V8i gives a good and clear structure which is easy to follow. Information
related to each object can be found and it enables the user to follow the changed modifications made
through the PTL file's history. However, the software doesn’t have any “redo” function to redo the last
change, e.g. if wrong object is moved or if wrong color were applied.
The function ClipBox is a very effective tool to change the volume of the area to be visualized by the
point cloud. It is a quick and easy way to create focus on a specific area which also provides noticeably
faster loading of data displayed, relatively if all cloud points would be shown. It is also a great tool to easily
prepare an export of a specific area, which reduces the file size.
The measurement function of the software is one of the most useful tools. Measurements between two
points, which generates a distance, can accurately be measured even at inaccessible locations, such as high
up in buildings or right through different objects. The position of the points selected can be easily checked
visually using smooth navigation and printed start and end coordinates.
The possibility of setting out single points whose coordinates are shown clearly offers the opportunity to
measure and get the coordinate of each individual point of the point cloud. Point measurements, similar
to those made with total stations, can be easily done with just a few mouse clicks. The ability to apply the
color scheme in a selected axis direction also allows the user to visualize the unevenness of e.g. the floor
surfaces, using a HUE-scale.
However, the software lacks the ability for the user to search for specific coordinates, i.e. indicating only
the x and y coordinates and thereby locates the associated z coordinate. Similar to single point
measurements, notes can be attached to any point enabling simple communication with other users where
relevant information or changes concerning the object can be described.
The tools to edit the points in the cloud such as selecting, coloring, hide points and move objects creates
new possibilities for the user of the scan results. The user can select and copy scanned points, import new
models which can be moved around to test new configurations of layouts.
It is rather easy to edit and hide noise from the scans, although the noise is not that annoying if the
planning of the scans was done properly and the surrounding was calm. The individual items can be
moved or rotated manually by pulling the coordinate axes or by entering the coordinates for the selected
object's local coordinate system. Another way to move an object is by selecting a point on the object
which should be placed in the same position as another selected point. This can generate a fast relocation
of the object but since the software is unable to identify whole surfaces, this feature isn’t as effective as
common assembly MATE functions found in engineering CAD software where two surfaces are placed
parallel together or to a specific distance from each other.
Just as you can drag items into different positions by hand, you can choose to animate the way by placing
milestones the object should move to. The software then calculates a path for the object to follow. Along
this path clash collisions can be simulated, which is one of the most powerful features of Bently Pointools
V8i against Faro Scene. However, the object can only follow a complete route and the software itself
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cannot, in an intelligent way, figure out the best way for an object to get from start to finish to avoid
collisions.
From the animations, high definition video clips and rendered high definition snapshots can be created.
However, generating a video file directly in Pointools often results in stops and crashes of the software. A
better solution is to save the generated frames in the created video and then use other movie rendering
software to create a video.
4.3.2.1 Machining
In the machining area that was scanned the production engineers were unsure of how accurate the layout
drawing used as a basis today actually are compared to reality. For a place with quite a lot of machinery
and equipment like this, Bentley Pointools V8i can be used effectively to compare how the layout relates
to reality by merging a layout DXF file with the point cloud, Figure 17.
Figure 17. Comparing the layout to the point cloud.
By these comparisons, one can visually see how well an installation has been carried out and measure if
the equipment is placed on the right coordinates.
Pointools also makes it possible for the engineers to clean existing areas or move the old machines, which
might not exist digitally, and simulate machine installations before they are implemented on site, Figure
18.
The production engineers can also, if necessary, move complete machine groups if for example the
production needs to be moved to another building and gain accurate information about the ceiling.
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Figure 18. Erasing one machine and importing a new 3D model in its place.
Measurements can also be made during production in areas such as robot cells. Dangerous areas or
specific areas may also be colored so that they visually stand out in the cloud and notes can easily convey
information, Figure 19.
Figure 19. Distance measurement on robot and highlighted floor.
4.3.2.2 Assembly
In assembly areas or other open product flows, laser scanning and the Bentley Pointools V8i software can
contribute with several improvements.
Since the rear axle assembly line that was scanned is very long, the resulting scan data will take a lot of disk
space and computer power. Therefore the ClipBox tool can be used to narrow down the area of interest
which also eases the processing of data. Besides being able to freely move around in an area that is usually
in full production, one interesting feature is the ability and possibility to simulate new products in an
existing flow without physically affecting the actual production.
A realistic usage of the scan material and working process of the rear axle assembly line is to first place all
the product carriers in the line in a hidden layer. Then one of the carriers could be duplicated and moved
to the beginning of the line. A new 3D model of the product, in this case a slightly larger axle, can be
imported and placed on the duplicated carrier. The two objects can then be animated through the
assembly line with a clash collision analysis of the path. The resulting collisions will then be highlighted
through the animation path.
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By using Pointools V8i, production engineers and designers can validate new constructions or products at
an early stage, e.g. verifying if new products fit and used in existing fixtures or equipment, Figure 20,
which can reduce project lead time development and reconstructions.
Figure 20. Importing a 3D model to verify new product in existing production line.
An assembly line as this is cluttered with tools, robots, people and products that are constantly in motion.
This can make it difficult to measure larger distances within the area which can be blocked by objects and
affect production if using laser distance meter or measuring tape. With laser scanning, however, accurate
measurements can be done offline without either affecting current production or having to worry about
blocking objects.
4.3.2.3 Facility management
For employees working with installations and construction design in buildings, such as ventilations, media,
walls and floors, the Bentley Pointools V8i can be used for several different applications.
Installations in the ceiling can easily be isolated with the ClipBox function, Figure 21, and the differencing
function can be used to compare for instance new CAD models of ventilation pipes with the existing
pipes to verify the designs.
Figure 21. Point cloud showing ventilation and media installations in the ceiling.
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In buildings were the floor unevenness is unknown measurements of single points can be taken and a
color HUE-scale can be applied to better visualize floor subsidence, Figure 22.
Figure 22. Point measurements and visualization of the floor unevenness.
The points and distances measured in the point cloud can then easily be exported to Microsoft Office
Excel, Figure 23.
Figure 23. Measurements exported to Microsoft Office Excel.
4.3.2.4 Aftermarket service
The Scania aftermarket service and method engineers gains the possibility to verify new service tools and
vehicle models in an accurate virtual environment of the service station, Figure 24.
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Figure 24. Moving and verifying different vehicle models.
3D CAD models, scanned trucks or busses and newly developed service tools can be moved around to
make sure they fit and, when in POD-format, any measurement can be collected between walls, tools and
vehicle in the early design stage digitally without visiting the actual location.
4.4 Cost calculations
This cost section presents the expenses of purchasing, usage and maintenance of scanning. It also presents
the problems within the company that led to costs which would have been possible to prevent with
scanning. It also recognized the savings that scan contribute. To investigate whether laser scanning can be
profitable for industrial companies, relevant parameters are calculated into a Scania MIKA-calculation,
which calculates the profitability of an investment in production equipment (Lindegren & Hilbom, 2006).
4.4.1 Expenditures
The expenditure concerning laser scanning varies depending on the approach of the company since it can
be performed either internally, where all the equipment is purchased, or when external consultants are
hired to conduct the scan.
4.4.1.1 Internal scanning
The largest cost in the case of scanning is the purchasing of the scanning apparatus. The price varies
depending on the manufacturer, the quality and bargaining. Based on scanning devices that are suitable
and recommended by each manufacturer to be applied in industrial applications, the following list prices
were found, Table 5.
Table 5. Price of laser scanners (Faro, 2013; Leica, 2013; Trimble, 2013).
Laser scanners Price (KSEK)
Faro Focus 3D ~ 330
Trimble TX5 ~ 330
Leica P20 ~ 500
If a company would decide to start scanning themselves they would need to buy additional equipment
apart from the scanner, such as tripod and references, which then can be purchased as a starter kit (Berlin,
2013). Costs of education, equipment service and software licensing should also be included in the
calculation, Table 6.
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Table 6. Investments and costs for internal scanning (Berlin, 2013).
Product Price (KSEK)
Service/license (KSEK)
Comments
Scanner Starter Kit ~400 100 / 3 year Faro Focus 3D, reference system, Faro Scene
Bentley Pointools V8i 60 12 / year
Employee ~16 Education
4.4.1.2 External scanning
Another option is to hire a consultant who is responsible for the capture of data and the registration of
the point cloud. However, the software used is still paid as in the case before. Consultant prizes are
difficult to specify as these often are priced individually and depend on the extent. The calculations made
are based on the price of the case study scanning in this master thesis which was 50 000 SEK for one
weekend (Berlin, 2013).
4.4.2 Earnings
Cost of errors and costs that could be avoided with laser scanning can be divided into recurrent costs and
known errors. This is based on statements of employees with knowledge of the errors and problems who
estimate that the technology with high probability could have had reduced or prevented the costs.
4.4.2.1 Recurrent costs
For larger redevelopment project the measuring of the building is usually performed by external
contractors, at a cost of 90 000 SEK (Johansson, 2013). This cost is divided into measuring of beams,
pillars, walls and ceilings that lack digital documentation and surveying and marking of physical reference
points. However, the measuring and marking of the references must be made regardless in order to
provide references for the physical installations in the building. With the additional surveying possible to
be performed in a point cloud, it is estimated that 45 000 SEK would be saved (Johansson, 2013).
It is worth mentioning that several smaller measurements of floor unevenness are performed before
machine installations, ordered by production engineers but performed by external contractors (Lord,
2013).
4.4.2.2 Known errors
In discussions with several employees at Scania and DynaMate, layout and installation problems emerge
that could have been avoided by using the scan result.
When installing machines and a gantry robot in building 075 a small change in the drawing that was not
discovered led to a misplaced machine which had to be moved 130 mm for 40 000 SEK (Andersson,
2013). A stop in the engine assembly line, to a cost of 200 000 SEK due to a collision between the product
and machine, would probably have been indicated and avoided if simulated in a point cloud (Bergman,
2013).
For installations in the engine processing, the buildings are not standardized and production engineers
lack proper documentation about ceiling heights. During installation of new machinery, production
engineers are concerned about problems relating to ceiling heights whereupon beams and pillars are
moved and rebuilt in order to make room for the machine at great expense (Gustafsson, 2013). However,
these costs are often included in the project budget why these are difficult to estimate.
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Furthermore, it has occurred installation errors due to incorrect layouts which has not led to any direct
costs, seen today, but may lead to future secondary faults. In building 062, errors in the layout resulted in a
machine partially installed in the truck path (Mårtensson, 2013).
4.4.3 MIKA calculation
Based on previously mentioned expenditure and earnings, two payback calculation cases have been
developed based on the internal Scania MIKA-calculation template. This is done in order to estimate
which method, internal or external scanning, that is most profitable the coming years.
4.4.3.1 Internal payback calculation
The result of the internal payback MIKA calculation, Appendix B, result in a possible payback time of 4,3
years, Figure 25.
Figure 25. Result of internal scanning calculation.
4.4.3.2 External payback calculation
The result of the external payback MIKA calculation, Appendix C, result in a possible payback time of 2,6
years, Figure 26.
Figure 26. Result of external scanning calculation.
4.5 Factory Scanning Process
As a result from observations, research and preformed scanning sessions at three different locations, a
new process method has been developed as an Astrakan process model (Astrakan, 2010) for the use of
laser scanning at Scania, Appendix D.
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There must initially exist a need of laser scanning results as an input or trigger to start the factory scanning
process. The process is divided into three major parts were the first two depend on the existing laser
scanning basis. If no previous scans has been made or the existing has gone out of date the two first parts,
the scanning and processing, first needs to be performed in order to gain a usable point cloud, Figure 27.
Figure 27. Factory scanning process.
The actual need is satisfied through the use of the point cloud and the two previous steps are only
necessary process steps in order to reach the goal.
4.5.1 Perform scanning
The scanning process model contains the initial planning and execution of the actual scan at the
physical/actual location, Figure 28.
Figure 28. Perform scanning process.
4.5.1.1 Overview
When initially planning the scan it is important to consider certain aspects, such as:
Objects or areas of interest
Detail level
Ongoing activity
When arriving to the area of interest it is recommended to walk around and try to gain a understanding
and overview of the location. In order to plan the scanning correctly it is important to determine and
understand the goal of the scan. Find out if there are certain areas or objects of special interest and the
level of detail desired or required by the final user. Make sure that the area of interest is as clear as possible
and the ongoing activity is kept to a minimum to avoid unnecessary clean up of noise in the result. If the
scanning is preformed in a factory it’s recommended to scan when the production is down and no people
are present.
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If the scene do not require a high level of detail and the scan positions will be near of each other the
software can afterwards limit the shown point cloud to a chosen diameter which might allow other people
and moving machines to operate in the background.
4.5.1.2 Determine the scan positions
When knowing the surrounding, objects of certain interest and detail level requirements the scan positions
should be marked up in order to ease the scanning process and make sure that the scene gets scanned
correctly. This approach makes it easier to remember the scan positions and make certain that no views of
an object are hidden or forgotten.
The positions can preferably be marked with high visible orange paper stars, which are easily detectable
and visible in industrial locations and point clouds. When placing the positions, try to visualize how the
resulting point cloud would look like and optimize each scan by making as few scans possible to obtain
the required level of detail. Make sure that the scanner is not closer than 500 mm from the nearest object.
Since each scanning position results in a separate file, the total area will consist of all the individual scans.
If there are too many scans the final scan file will get huge.
If the distance between two scans is not far, but still necessary to scan, e.g. two sides of an object, the
range and therefore the detail level do not have to be set to the maximum since the scan points taken far
away probably will be covered by another scan, depending on the planning of the area.
4.5.1.3 Placing references
In order to be able to accurately merge the scans together reference spheres are used. Each scan point
should see at least three different reference spheres and at least one of those references should be
common with another scan. This means that each reference sphere should be able to “view” at least two
scan points, which is now easy to visualize and verify with the help of the previously marked scan
positions.
When planning, the reference positions are marked with a piece of tape because of the limitation of actual
(and rather expensive) reference spheres. This makes it easy to visualize and verify the scan area and it is
easier and quicker to make small changes with a piece of tape than a reference. Place the references as
high as possible, because high positions often can be spotted from several scans since objects most often
are at the floor level. Also try to position the references as far away from each other as possible to avoid
misalignments and angular errors when merging the scan positions together.
If a higher accuracy is required and the scans need to be transformed to an absolute coordinate system the
references could be measured relative a known position, with a total station. The references that are
measured are recommended to be fixed, i.e. permanently attached to the building or its constructions.
Notice that the references, the spheres, are attached with an magnet and it is the magnet that is attached.
This allows the spheres to be reused in other scans and enabling rescanning of the same area and merging
the old and new scan since the references are the same.
It is recommended to attach the permanent reference magnets on concrete walls or pillars instead of steel
constructions. Steel can be affected by the environment, such as heat, and may therefore change
properties. Slightest change of the reference base position, in millimeters, can affect the accuracy of the
new scan when merged together with an old scan.
4.5.1.4 Place references used for upcoming scan
The amount of reference spheres is often limited and the spheres themselves are more expensive than the
magnets. Therefore the same references will be moved and used for several scans and reference points.
The references available will then be moved to cover the current scan position and the next one. Since
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each scan require three references and at least one should be in common with the next scan, at least five
references will be occupied. Besides those five, the first and last scan will often share some references
since the scans are often made in some kind of circle. Since the first references also will be the last the
references won’t be allowed to be moved.
When planning the route it is important to make sure that you can move old and used references without
interfering with future scans. Make sure that once a reference is in place and has been scanned once, it is
not allowed to be touched or moved until the reference point is certain not to be used in another scan.
4.5.1.5 Scanning execution
The result of the scanning will be a captured “frozen state” from each scan position, much like a digital
picture but in 3D. “Shadows” will be represented as empty or “dead” points. When the scanner is placed
on the scanning position, aim the scanner to make sure that it has a clear and free view to the references
intended for that scan. Chose the first scan to a point with a large open space and as many visible
references as possible.
Before starting the scanner, turn the front of the scanner in a direction which is easy to orient since that
will be the “first view” when opening the scan. Also make sure that no references are in a straight line in
front or back of the scanner in its starting position because it may cause a split in the panoramic view and
complicate the identification and accuracy of the references. When starting the scanning and during the
scan session, especially after the scanner has taken laser distances and intensity measurements and is about
to start the digital photo shot, it is important to have as even lightning at the scene as possible and as
bright as possible.
The scanner will rotate very slowly and will only take measurement in a straight line crossing the scanner.
This makes it possible for the operator to walk around the scanner as it rotates to not intervene and block
the laser. Otherwise the crew and the objects not wanted in the scan have to be hidden out of view of the
scanner. For the best result make sure there is nothing moving during the scan (humans or machines)
since this will cause disturbances in the point cloud, shown as irregular points and may block objects in
the background. Also make sure to clear the area as much as possible.
An unwanted object, for example a box, might be moved between two scans covering two sides of the
box. In the merged point cloud of the two scans this will look like two boxes, but if deleting the boxes this
will result in a clear floor.
4.5.2 Perform processing
When the scanning has been performed the raw scan data collected has to be processed and merged in
order to turn into a usable point cloud, Figure 29.
Figure 29. Perform processing process
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4.5.2.1 Import to software
When the scan is completed, the data from the scan is saved on the Faro focus SD-card. The scan
positions are located in separated folders the SD-card and are easily imported into the registration
software by drag-and-drop functionality. The software will automatically unpack and convert the scans,
which take about one minute each.
After being imported each scan can be opened separately to be reviewed in 3D or panoramic view, but the
scans won’t have any relation to each other since they aren’t merged together yet. Measurements can
however be taken and the points may even be edited in the individual scan.
4.5.2.2 Registration of references and merge of point cloud
In order to merge the scans together into a joint point cloud, the references need to be found and
registered in each scan.
The software will automatically go through each scan and search for spherical shapes with radius matching
the references. With the help of the built in inclinometer in the scanner, the coordinate of the center of
each sphere found will be given an ID-number. The coordinate of the sphere will then be compared
relative other spheres found in the same scan. The relationships between the spheres in a scan are then
compared with the relationships of the spheres in other scans and if a match is found the identical spheres
will get the same ID-number. When identifying the relations between all the scans the complete point
cloud can be merged into one when placing the identical spheres at the same global coordinate.
The software might however detect and identify other objects incorrectly as reference spheres. In some
cases the automatic identification will miss to identify a sphere or incorrectly identify two separate spheres
as one. Such errors might result in disfigured merged point clouds. In such cases the user has to manually
delete or identify spheres retrospectively.
4.5.2.3 Transform point cloud and apply color
The point cloud will by default show the intensity in gray scale. In order to be able to export and show the
cloud in color the color pictures has to be applied to the scans.
At first, the merged point cloud will have the coordinate origin at the physical origin of the scan chosen as
grounded. However it is preferred to transform the point cloud by moving the origin and rotate the point
cloud to match a known building origin. The transform of the point cloud can be performed in two ways
depending on the preconditions. It can either be done manually by comparing chosen positions with a
drawn layout and move and rotate the point cloud by freehand by measuring beams or walls which
follows the building x and y axles.
Preferably, the transformation will be done by knowing the exact positions of some of the spheres. By
measuring three references spheres’ positions with a total station relative a known position in the building,
the known coordinates of the spheres can be given the spheres in the scan. This resulting in a accurately
transformed point cloud relative the building layout.
4.5.2.4 Export and convert point cloud
When the point cloud is correctly transformed it can be uploaded to an internet server and shared on the
web (Web-Share) with other users around the world. By reducing the volume of the point cloud to only
show a small shred about 150 mm above the floor, a 2D top view layout can be created. When uploaded
together with the scans, the 2D layout will also include the positions of the scans, making it possible to see
the panoramic view of each scan online.
The final step of the registration process is to convert the point cloud to a POD-file to enable future
modifications and simulations in Bentley Pointools V8i. This can be done in the registration software but
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is preferably done in the Bentley Pointools software. By filtering the range from which the points are
shown from each scan position and determining the density of the point cloud (the distance between the
points), the resulting POD-file can be held to a manageable size.
4.5.3 Use point cloud
The complete point cloud provides the user with several possibilities depending on the initial needs of the
scanning results.
What the scan results will be used for is up to the user. To present a strict model to be followed is difficult
since the user has its own agenda and may want to make few or many things with their scan results.
Therefore this process model is constructed as more general guidelines to reach different targets. The use
of the point cloud is divided into communication and visualization, gather information and simulation and
verification, Figure 30.
Figure 30. Use point cloud process.
4.5.3.1 Communication & visualization
The point clouds can easily be used as a visualization tool for meetings or simply to refreshing memories
of a location. The possibility to view and examine a location remotely, far away from the actual location
which might even be in other parts of the world, and the ability to add notes of descriptions or attached
documents also makes it to a useful tool for communication. The different available software provides
easy access to panoramic views of the scanned location online or the possibility to fly around in 3D with
the option to view the scan in either color or intensity.
4.5.3.2 Gather information
The point cloud contains a huge amount of information about the scanned location concerning
measurements. Depending on the needs, the user can take measurements of single points or distances
between several points. Measurements can be taken from any point in the point cloud and distances
between two points can be made without the concern of interfering objects in between the points. By
measuring several single points the user can evaluate the flatness of surfaces, such as floors, without the
need of hiring external measuring consultants. The user can also apply a color scale to visualize the
unevenness of the floor.
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4.5.3.3 Simulation & verification
The main advantage of using point clouds is the ability to edit and modify the point cloud and with the
help of the software performing advanced simulation and verification of existing layouts, models and
installations. The user is able to colorize, hide, remove, duplicate or transform the points. Existing
installations, e.g. machines or ventilations, can therefore be copied or moved to new locations. Existing
2D layout drawings or 3D models can be attached and verified relative the point cloud. The attached
objects can be simulated with clash collision or differencing, making it able to test installation paths of
new machines and verify simulate how well the new machines or equipment will fit in the existing
building.
4.6 Factory Scanning Process implemented in the Factory Design Process
As a result of this master thesis, a proposal has been developed of how the Factory Scanning Process in
section 4.5 can be implemented in the Factory Design Process, section 3.2.2, and thus be practically used
in the layout development projects.
In order to follow the same detail level in the process model some minor modifications had to be made in
the activities of the Factory Scanning Process. The content of the activity use point cloud will now be seen as
a resource such as scan data information and the software Faro Scene and Bentley Pointools V8i,
appendix E. How the laser scanning can be performed and utilized in the factory design process is
described below, divided into the three phases of the main process.
4.6.1 Pre-study
After the conceptual solution and condition of the building has been developed, a decision must be made
if a point cloud, as a result of laser scanning, is needed. This decision includes determining whether a new
scan should be made or, if a previous scan already exist and is not out of date, it is possible to use an old
point cloud.
The process Perform Scanning generates raw scan data which is then used in combination with the software
Faro Scene in the following process Perform registration. The processing generates a complete usable point
cloud back to the scan data information. The cloud point may then, with the aid of the resources Bentley
Pointools or Faro Scene, be used in the development of the rough layout and assess the work of
determining the consequences for the property.
4.6.2 Project planning
The combination of scan data and software can facilitate the work with several major processes in the
project planning stage. Parts of the point cloud can be used as basis for quotation work, where selected
parts of the specific areas also may be sent to suppliers to facilitate their work with the construction
design.
Furthermore, the scan results can be used to more clearly and effectively verify and develop a "best guess"
layout, where for example new machines from suppliers and the installations can be simulated. The scan
result can also be used as a tool for creating the detailed planning.
4.6.3 Final planning and installation
During the final planning the scan data would be an aid to produce construction documents. Through
validation and simulation in the point cloud the layout can be “frozen” which would secure and ease the
physical installation of equipment.
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When the installation is done, the layout should be updated to a new Current situation. By performing the
scanning process again, the theoretical layout can be compared with installed reality, and thus verify the
proper installation. This new current situation is saved and can thereby be used as a basis for the next
project of the same area.
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5 Analysis and discussion This chapter will discuss and analyze the results from the case study and the findings from theoretical framework, in order to
find answers to the research questions.
5.1 Technology and applications of laser scanning
This section is divided to firstly present the technology of the laser scanning and later the useable
functions of the software tested.
5.1.1 Technology of laser scanning
The technology of laser scanning is not that new. However, the software has seen a drastic development
in recent years. The modern programs have become more efficient and have introduced new applications
and the technology. They can handle larger point clouds, in color, perform animations and simulations.
The scanner performs a quick collection of the data with high accuracies. The laser scanner accuracy
meets Scania’s general demands of the layout drawings. The final accuracy and quality of the scan result
can however largely depend on the user. Using the scanner is relatively easy since the interface is user
friendly and the scanner is highly automated in terms of data collection and point measurement. All
distances, angles and rotations are calibrated and calculated automatically by the scanner and the user gets
the data on a portable memory.
To get a satisfying result requires good planning. By gaining a quick overview of the area and understand
the main applications of the result, the level of detail and especially interesting items can be determined.
Regarding the quality, Staiger (2005) states several parameters which influence the scan result in a negative
way, which many of these can be avoided with proper and carefully planned execution. As an example,
when measuring points of surfaces such as floors which requires accurate measurements the scanner
should be placed as high as possible. This is to minimize the angle of incidence to the surface and thus
obtain more accurate measurements.
Common errors found in the results of the case study that can still occur regardless of the planning
include errors that occur due to material properties of the objects being scanned. If an object is scanned,
standing behind a transparent material (plastic or glass, for example) or in front of a mirror, the material's
refractive index will affect the perceived positioning of the object in the point cloud. This will result in
noise or even disorientations in the resulting point cloud, Figure 31.
Figure 31. Noise due to reflections.
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5.1.2 Usable features of the software
From the results of the case study multiple uses for laser scanning were found. Almost all Bentley's
features can be used regardless of business area within Scania. Even if the three locations in the case study
are different, all the layouts are able to be comparable to the point cloud. All locations also had benefits of
importing models and taking measurements. Since Bentley Pointools V8i is user friendly the education
among the potential users should go smooth without dedicating too many resources.
One of the discovered disadvantages of the software handling point clouds is the computer capacity
required to run the animations smoothly. The point cloud grows linearly for each scan added which
demand even more computer performance. Thus a balance must be made between the size of the point
cloud and the available computer performance. One option is to change the density of the cloud which
erases some of the points and result in a smaller file size, but that may also erase important points for
future users. Another option is to always change and export a specific volume using the ClipBox function.
This can be good when sending only need-to-know information to suppliers and it lowers the computer
requirements, but the user will also lose the whole overview and information not shown still has to be
found in the original file.
A third option is to clean noise (disturbances) or overlapping surfaces in the point cloud which will both
make the point cloud tidier and smaller. It might however be dangerous to erase to much noise, but what
might seem redundant to one user might be relevant for another. If approved, the changes must be done
in individual PTL-files were the original file impossible to destroy.
The applications presented in section 0 can both facilitate the work of verification of models and layouts,
and simulate events. This means that errors can be detected and prevented earlier than in the current
situation and lead times in projects can be reduced. This also allows early digital testing of newly
developed products in the existing production environment, which is one of Volvo’s goals.
A new application area that should be able to save money in the long run is to replace conventional
control measuring of floor, made by contractors using total station, with laser scanning. The laser scanning
can both provide measurements for the floor as it can be used for simulation and other applications for
other users. The same point cloud can thereby be used by many stakeholders.
If solid guidelines are created for what each software can be used for within the company, an
implementation of the technology can become smoother. For example, if Bentley Pointools V8i is used by
the general users for common work in point clouds, a selected few who might also perform the scans can
work with registrations and the creation of Webshare in Faro Scene. The Webshare service can be used by
anyone, which also means that security levels has to be taken into consideration since the content include
large amount of classified information.
If comparing the features of Faro Scene and especially Bentley Pointools V8i with Chen et.al. (2012)
report one can find that many features meets the requirements of a layout software. Although, in many
cases flaws in the software will not make any of the two software alone to be considered as complete and
flawless layout software. Bentley is, however, good in terms of coordination of various models, as multiple file
formats can be opened and compared simultaneously. This could conceivably also facilitate cooperation
with different suppliers, who might have a different file standard.
PTL-files read in Bentley can consist of and retrieve information from many common files, making
changes and modifications of the files also affect the PTL-file. This meets the requirement of management of
change and logistics. The user must however critically evaluate the result since the software sometimes might
fail to import, open or show certain details. Another disadvantage concerning the management of change
and logistics is the lack of aid concerning the file handling. The files are often large which demands some
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kind of PDM/PLM-system supporting point clouds in order to control the fast growth of files, thoughts
that seem to be shared with Volvo Cars (Rönnäng, 2013).
As presented in the results using Bentley Pointools V8i is also an effective way to perform verification of
layouts and new models in the real environment. However, Bentley Pointools V8i lacks what Chen et.al
(201x) prefer to as Creation of layout models, where the ability to draw and create new models are not
supported by the software. Even if Bentley Pointools V8i satisfies many of the criteria of the article, it is
still not developed to be a layout program. It is a software with the special purpose of managing and
handling point clouds.
However, were Bentley Pointools V8i doesn’t meet the criteria LayCad does, and vice versa, meaning that
the two likely would be able to complement and support each other to meet the criteria for a useful layout
program according Chen et.al. (2012). Today, Bentley Pointools V8i can be a complement to LayCad in
terms of verification and simulation of the layouts and different models.
5.1.3 Conversion to CAD models
To convert point cloud to CAD format and thus make points to solid surfaces are in the current situation
not fully established as the technology is not fully developed. When it comes to scanning of complete
factory environments, this is not such a desirable function today for Scania, where the focus instead
should be to verify CAD models in the point cloud and not vice versa. This is due to the large resulting
files and the loss of accuracy from the point cloud.
5.2 Cost analysis
The cost calculations in the result chapter were based on two possible cases, buy equipment and scan
internally or hire consultants who performs the scanning and registration process. In both cases, the
software Bentley Pointools V8i will be used internally.
It is however difficult, or even impossible, to speculate if laser scanning can provide payoff or not based
on mainly estimated figures about future mistakes that will lead to costs, that might as well never happen.
Looking in the past however, there are a number of costly incidents that relatively easily could have been
prevented and avoided if laser scanning had already been established within the company. On the other
hand, if the result are not taken care of properly and used wrongly, the investment would only have been
expenditure.
The result shows that the external measuring using total stations and external consultant laser scanning
almost cost the same. The fact that multiple stakeholders later can draw benefit from the same scanning
result is a bonus.
Whether the execution of the scanning should be performed internally or externally mainly depend on the
extent and costs. One alternative is to scan all workshop areas at once. Another option is to start scanning
areas that are in need of the scan result and allow the scanning to spread gradually through the company.
To directly scan everything would likely result in a huge cost since most of the scan result probably
wouldn’t be used correctly before it became out of date, without first establishing the scanning culture
within the company. Another factor working against scanning everything immediately is the previously
mentioned lack of PLM-system for managing the large amount of files which would quickly arise.
A realistic alternative for Scania would be to begin to scan workshop areas gradually, where the scan
results immediately can be seen as useful, with the help of external consultants. The result also shows that
the empty space is the most time efficient to scan considering scanned square meter per hour, since larger
open areas allows a few scans to cover the whole area. This isn’t surprising but an indication of when to
scan most time and cost efficiently if one gets the opportunity. As for the file management, the gradual
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approach would not overwhelm the users of new scan files before a system is put into operation and the
question concerning the ownership of the files can be evaluated and established during time.
Volvo claims that Ford sees the profit of laser scanning in reduced travel costs and increased availability of
their engineers, who instead can view the scan results. On the contrary, employees at Scania claims that
the trips usually needs to be done regardless since the personal contact often is important and that other
issues and problems are discussed during the visits. However, it would be desirable to make more visits at
other production sites only for visualization which cannot be funded today, thus scanning could be
purposeful in those cases.
Overall regarding the economy of laser scanning at Scania, profitability exists both through calculations
and the general belief in the technology among the employees and its ability to save money.
5.3 Scanning process model analysis
The processes Factory Scanning Process and its implementation in the Factory Design Process are
analyzed and discussed individually in this section.
5.3.1 Factory Scanning Process
The developed Factory Scanning Process model shows the entire scanning process, whether a company
choose to scan internally or bring in external resources. The process model is intended to illustrate how a
user should perform the scanning process to achieve even results, regardless of previous experiences, in a
simple and educational way.
Since the process model is based on the observations of three scanning locations, without further testing
of the model in this thesis, it should be seen as a first concept which can surely be improved. The process
does not specifically deal with the case where the reference spheres are measured with a total station
relative to known references in the buildings, which would probably result in additional process activities.
However, this case should be considered before starting scanning since using the total station result in
significantly improved accuracy and confidence in the point cloud. The known position in the coordinate
system of the actual building simplifies the validation of layouts and 3D models since they all share the
same origin. To mount the fixed reference fixtures is also a precondition for being able to update existing
point cloud.
As the processes for use point cloud are highly individual, depending on the user's needs, this process is
best viewed as a suggestion of how the software can be used to effectively facilitate work processes.
5.3.2 Factory Scanning Process in Factory Design Process
A further result of this master thesis was a proposal on when and where the activities from the Factory
Scanning Process could be implemented and used in the Factory Design Process.
The developed process provides a clear overview how scanning can and should be used. It shows that
several activities in the layout process can make use of and be supported by the scan result and software.
The features of the laser scanning software can be used for both validation and communication between
different departments within a company. It also shows how multiple stakeholders in the projects can
benefit from using the same basic scan data in different ways and for different purposes. However, there
are some problems that should be discussed and sorted out before scanning is implemented within a
company.
Firstly, it must be determined to what extent the scan should be implemented. Depending on the overall
objective and general faith in the technology, a company can either choose to scan everything immediately
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and then update small parts or scan a selected portion of a project and see how the scan is spread
gradually in the company.
Secondly, the process model divides the responsibility of different tasks among Production Engineers,
DynaMate, Machine Suppliers and “Scanner”. It needs to be determined, especially if the scanning is
performed internally, who has this “Scanner” responsibility. This also includes solving who is the owner
of the scan material.
Thirdly, it has to be determined how the information generated both from the data capturing and the daily
work regarding point clouds should be saved. The files may initially be saved separately in folders related
to the relevant building area and layout files, similar to the file structure used for managing LayCad files
today.
Before taking the method of laser scanning to any larger scale within the company some sort of PLM-
system supporting point clouds should be implemented, which also should include features like scan date
and point cloud revision level.
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6 Conclusion This chapter comprises the output to the four research questions introduced in the first chapter of the thesis and some Scania
specific recommendations.
6.1 Result of the research questions
Concerning the output of RQ1, laser scanning can facilitate the work process regarding three main
applications, presented below.
Applications that can facilitate the development and maintenance of production systems
within manufacturing industries.
Visualization & Communication: The point clouds can easily be used as a visualization aid for
meetings or simply to refreshing memories of a location. Providing the possibility to view and
examine a location remotely, far away from the actual location which might even be in other parts
of the world. The ability of the point cloud to be an information carrier in form of adding notes
of descriptions or attached documents makes it to a useful tool and a decision base for
communication.
Gather information: The user can take measurements of single points or distances between several
points. Measurements can be taken from any point in the point cloud and distances between two
points can be made without the concern of interfering objects in between the points. This also
enables evaluations of the flatness of surfaces and the ability to a color scale to visualize the
unevenness of the floor.
Simulation & Verification: The software can perform advanced simulations and verifications of
existing and future layouts, models and installations. Parts of the scanned point cloud can be
colorized, hidden, removed, duplicated or transformed. Existing 2D layout drawings or 3D
models can be attached and verified relative the point cloud. The attached objects can be
simulated with clash collision or differencing. This can simulate how well new machines or
installations will fit and be installed in the existing building or if new product geometries fit in
existing production as well as verifying CAD models.
The output of RQ2 is presented below.
Usage within other automotive industries.
Major automotive companies: Many other companies are working actively with laser scanning today,
such as Toyta, Mercedes and Ford. Their main focus is to scan robot cells but most of them are
facing trouble and turn to Volvo Cars for support.
Volvo Cars: Today Volvo Cars in Gothenburg is one of the world leading companies when it
comes to using and developing laser scanning within the automotive industry. Strategic
investments of virtual manufacturing motivated further investment and the profit is a god
visualization tool as a discussion base for communication and a tool for simulation and
verification of products and processes digitally. Today Volvo uses external consultants to perform
the scanning but they aims to do the scanning themselves in the future.
o Positive experiences
3D model of reality
Great visual tool for communication
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Verify layouts
Simulation and validation of new products
Decreased travel costs – higher engineer availability
Generally positive reception of the technology
o Negative experiences
Large data files – disk space demanding
File structure – no available PLM solutions
Update of point cloud
The output of RQ3 is presented below.
Profits gained with the laser scanning approach
Reduce installation errors: By simulating and verifying layouts and machine installations before
implementing the changes, costly mistakes and rework can be prevented. Increasing the security
and reliability of the installation basis and increase the layout accuracy. This also creates an
understanding and measurability of the ceiling and media installations which usually is absent in
today's drawings.
Replace current method of measuring: Measuring in the facilities, both for control of the layouts and
finding the flatness of floors, currently done by contractors can be performed in point clouds.
Laser scanning also gains access to otherwise confined spaces.
Travel costs: By doing virtual study visits airline ticket fees and large amount of time can be saved
for longer trips. Shorter distances within the factory for control measuring and refreshing
memories can be reduced, save lots of project time.
Increased understanding and communication: Since the webshare applications can be easily used without
any specific knowledge about CAD or drawings and with no risk of destroying the data, it can
support and streamline the general understanding of the workshop areas and the communication,
helping making better decisions.
The output of RQ4 is presented below.
Scanning implemented in the Factory Design Process
Factory Scanning Process: The factory scanning process model can effectively be used to perform a
scanning and use its result. The illustrating process and the descriptive text provide the users with
a simple guideline towards an even result, regardless of previous experience.
Factory Design Process implemented in the Factory Design Process: The result of the implementation of the
Factory Scanning Process in the Factory Design Process shows that the laser scanning technology
and methodology can be used and facilitate several activities during the layout development. It
shows that laser scanning indeed can be a good tool to support the work process and streamline
the whole project process, which are likely to reduce project lead time and increase the quality.
6.2 Recommendations to Scania
With support from the analysis and the conclusions some specific recommendations to Scania, if the
company decides to invest in laser scanning and wants to start implementing the technology.
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Start with consultants: The actual scanning is not necessarily so difficult to perform. However, the
cost analysis shows that it is cheaper to allow consultants to scan in the short term. Therefore it is
recommended to wait to buy an own scanner before the method has gained a foothold in the
company and since the technology probably will develop even further. The consultancy market
also offers several alternatives why price can be negotiated. Since all the examined scanners are
quite similar therefore and supported by Bentley Pointools V8i the choice should be based on the
best price and service.
Measuring and fixating references: Make sure to measure the base references to known coordinate’s
relative the building origin increase the accuracy and usability of comparing layouts and models
with the point cloud. To enable accurate and smoother rescanning all the reference points should
be fixed.
Start scanning new projects: Spread the knowledge gradually within the company and start to scan for
projects where a clear need exists and a payback can be relatively easily counted.
Organize the file management: Before any large-scale scanning begins one should wait for a
functioning PLM-system in order to manage the large amount of files. Until then, it is possible to
use a clear file structure, similar to the one used for LayCad today.
Solve responsibility & ownership issue: Try to investigating who should be the owner of the material
generated and who should be responsible for not letting any outdated point cloud being used.
Usage of scan result: Use the scan result to verify and simulate CAD models and layouts in the point
cloud, not to convert the point cloud to CAD. Laser scanning will probably not be able to replace
2D & 3D layouts entirely, but it can be a useful complement in order to perform verification and
simulation.
62
63
7 Future work During the study some areas where detected were further studies would be appreciated. The subjects presented in this chapter
were considered as out of bounds for this thesis but would be interesting for many stakeholders concerning laser scanning of
manufacturing industries.
Since this thesis main goal was to examine the usability of the laser scanning technology and the
laser scanning process, further studies can investigate how the actual implementation of the
technology within Scania should be made.
Scania should continue to examine the retailer market concerning different suppliers and systems.
Scania had a wish to test Bentley Pointools V8i due to the use of Bentley software at Volkswagen,
but the company should continue to evaluate and test other processing software.
As many stakeholders actually had a wish of exporting point clouds to already established CAD
systems. Therefore further investigations concerning CAD software plug-ins can be done.
The problems associated with file management should be studied in order to map the possibilities
of different PLM-suppliers.
Another interesting field is to investigate how the point cloud can be more intelligent to recognize
objects and implement kinematic properties to the scanned objects.
64
65
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2-1
20
-12
-12
0-1
2-1
20
-12
-12
0-1
2
Oth
er
Support
frå
n A
TS
-50
-50
-50
-50
-50
-50
-50
0-5
00
00
00
00
00
Sum
Oth
er
(KS
EK
)-5
00
-50
-50
0-5
0-5
00
-50
-50
0-5
0-5
00
-50
-50
0-5
0-5
00
-50
-50
0-5
0
Op
era
tin
g C
as
h F
low
00
00
00
00 0
Sum
Pers
onnel (K
SE
K)
00
00
00
00
00
00
00
00
00
00
0
Su
pp
ort
an
d M
ain
ten
an
ce
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
Support
and M
ain
tenance (
KS
EK
)0
00
00
00
00
00
00
00
00
00
00
Op
era
tio
ns
Byg
gnader
i behov
av
uppm
ätn
ing f
ör
nya
insta
latio
ner
75
-45
-90
62
-45
-90
?-4
5-9
0-1
50
-270
?-1
50
-270
?-1
50
-270
?-1
50
-270
?-1
50
-270
?-1
50
-270
Sum
Opera
tions (
KS
EK
)-1
35
-270
135
-150
-270
120
-150
-270
120
-150
-270
120
-150
-270
120
-150
-270
120
-150
-270
120
Qu
ality
Undvi
ka f
el v
id a
rbete
med la
youte
r0
00
00
00
75
-40
00
00
00
00
00
150
0-2
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
Qualit
y (
KS
EK
)0
-40
40
0-2
00
200
00
00
00
00
00
00
00
0
Ad
min
istr
ati
on
00
00
00
00
00
00
00
Upplä
rnin
g f
ör
att
scanna+
info
ga 4
00kr
-16
00
00
00
00
00
00
0
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
Adm
inis
tration (
KS
EK
)-1
60
-16
00
00
00
00
00
00
00
00
00
Face o
ut/
clo
se d
ow
n t
he p
resen
t IT
so
luti
on
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
O
thers
(K
SE
K)
00
00
00
00
00
00
00
00
00
00
0
Oth
ers
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
O
thers
(K
SE
K)
00
00
00
00
00
00
00
00
00
00
0
Oth
ers
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Sum
Oth
ers
(K
SE
K)
00
00
00
00
00
00
00
00
00
00
0
-15
0
-10
0
-50
0
50
10
0
15
0
20
0
25
0
30
0
0
1
2
3
4
5
6
7
Net Present Value of Cash Flow
(ksek)
Ye
ar
Pro
fita
bil
ity C
alc
ula
tio
n o
f E
xte
rnal
Scan
nin
g
Get
an
overv
iew
Un
de
rsta
nd
ing
of
loca
tio
n
Dete
rmin
e s
can
po
sit
ion
sP
relim
ina
rily
se
lecte
d
po
sitio
ns
Dete
rmin
e r
efe
ren
ce
po
sit
ion
sP
relim
ina
rilt s
ele
cte
d
po
istio
ns
Pla
ce r
efe
ren
ces f
or
up
co
min
gS
can
P
lace
d r
efe
ren
ce
sS
tart
scan
Ra
w s
ca
n d
ata
Imp
ort
to
so
ftw
are
Sca
ns im
po
rte
dA
uto
mati
c r
efe
ren
ce
reg
istr
ati
on
sId
en
tifie
dre
fere
nce
sE
valu
ati
on
of
refe
ren
ce
Qu
alit
y r
ep
ort
Tra
nsfo
rm/A
pp
ly c
olo
rE
xp
ort
ab
le file
Co
mu
nic
ati
on
& V
isu
alis
ati
on
Ga
the
r In
form
ati
on
Sim
ula
tio
n &
Ve
rifi
ca
tio
n
Usa
ble
po
int clo
ud
Exp
ort
an
d c
on
vert
ed
po
int
clo
ud
Usa
ble
po
int clo
ud
Fu
lfill
ed
ne
ed
sR
aw
sca
n d
ata
Perf
orm
scan
nin
g
Perf
orm
pro
cessin
g
Use p
oin
t clo
ud
Ne
ed
of
La
se
r
Sca
nn
ing
Appendix
D
Perf
orm
scan
nin
g
Fu
lfill
ed
ne
ed
s
Perf
orm
pro
cessin
gU
se p
oin
t clo
ud
Usa
ble
po
int clo
ud
Ra
w s
ca
n d
ata
Facto
ry s
can
nin
g
pro
cess
Ne
ed
of la
se
r
sca
nn
ing
Fu
lfill
ed
ne
ed
s
Facto
ry s
can
nin
g p
rocess
Ne
ed
of la
se
r
sca
nn
ing
<Aktiviteterochinformationsflödevidverkstadsprojektering,UTKASTP1>
År1
År2
ResourceOlikaprojekt-/layoutstadier
ScannersKommentarerDynamate/projekt/anläggningScania/
produktionsteknikMaskinleverantör
Konceptarbete
Flöde
Blocklayout
Konceptuell
lösning
Skapagrovlayout/
planlösning
Grovprod-layout
Grovplanlösning*
Grovt
mediabehov*
Tafram
kalkylunderlag:
Maskininvestering,
Fastighet
PVA
Göra
kravspecifikation/
förfrågan
Bedöma
konsekvenserför
fastighet/media
samtåtgärder
Förslagoch
kostnadsupp-
skattning**
Alt.layouter
Detaljprojektering
Handlaupp
utrustning
Utrustning
upphandlad
Förfrågnings-
underlag
upphandling
Slutprojektering
”F
rys
a l
ay
ou
t”Frystlayout
Bestguess
Upphandlad
entreprenad
Tafram
bygghandlingar
Entreprenadmed
bygghandlingar
Installera
utrustning
Installerad
utrustning
Uppdateralayout
efterinstallation
relationshandlingar
Layoutasbuilt
Förstudie
Projektering
Slutprojektering/
installation
Underlagetinteklartförrän
maskinerhakonstruerats
**
Pri
sin
dik
ati
on
so
m s
va
r p
å b
yg
g-
och
me
dia
ka
lky
lun
de
rka
g
1. M
aski
nin
stal
lati
on
sko
stn
ad2
. Fas
tigh
ets
inst
alla
tio
nsk
ost
nad
3. Ö
vrig
a fö
rbät
trin
gsfö
rsla
g4
. Ko
mm
en
tar
på
gro
v ti
dp
lan
Flödesdiagram,VSM
Bedöma
möjligheter
ochstatus
ombyggnad
Undersökningomfundament,om
detbehöves,ställverk,
grundvatten,sprängning…...
Modifiedby
JonasAndersson&JohanSvedberger
Original:DanfangChen
Blocklayoutmedflöde
Grovlayout,
”skis
s”
Preliminärdetaljlayout,
”b
est
gu
ess”
Leverantörsdetaljlayout
till ”
fryst”
layo
ut
Medialayout
Förutsättningar
Kalkylunderlag
*Grovproduktionslayout/mediabehov/
planlösning-byggochmediakalkylunderlag
Kortabeskrivningarkring:
1.Antalmaskiner
2.Groveleffekt
3.Antalpersoner(vidmontering)
4.Antalfundament
5.Antaltungalyft
6.Pausrum/matrum/personer
7.Antalkontorsplatser
8.Antalkvadratmeter
9.Processutsug
10.Kylbehov
11.Toaletter
Övrigauppgiftersombörfinnasibilaga:
Grovlayout,grovtidplanmedevetapper
Offertarbete
Kravspecifikation/
förfrågan
Beslut
Utvecklaalternativa
layoutersamt
”b
es
t g
ue
ss
”
Offereradlösning
Order
Specificera
Mek/inst
Media
Bygg
Kravspec
anläggning1.0
ÄTA(ändrings-
&tilläggsarbete)
PMändrade
handlingar
Asbuilt-nyttnuläge
Konstruerad
utrustning
Konstruktion
RawData
Perform
Scanning
Perform
Processing
Usablepointcloud
Needofscandata
Scandatainformation
FaroScene
BentleyPointools
RawData
Needofscandata
Usablepointcloud
Perform
Scanning
Perform
Processing
AppendixE