Introduction
Accurate layout data is the backbone of effective plant expansion. When a leading industrial manufacturer planned to install a new Power & Free (P&F) Conveyor in their assembly section, they faced a significant hurdle—no existing layout drawings. With crucial details like column positions, truss structure, HVAC, roof drains, piping, and conveyor paths missing, the client needed a reliable as-built model to move forward with confidence.
To solve this, the client partnered with Production Modeling India (PMI) to carry out a precise Point Cloud to 3D conversion of the assembly area.
Client’s Challenge
The client is a world-leader in the automotive manufacturing industry, with specialties in body-in-white closures, exhaust systems, and closure production equipment. Known for their Full Vertical Approach, they provide integrated turn-key solutions that range from product design and tooling through mass production.
This integrated system enables them to deliver quick vehicle development cycles while maintaining quality standards. In order to confirm the strength of a new production line and confirm its performance prior to implementation, the client hired PMI to perform a simulation-based study. The objective was to determine system throughput, find constraints, and identify optimal buffer strategies throughout the line.
Production Analysis in Car Manufacturing Industry - Case Study
PMI’s Approach
PMI took a structured and scalable approach:
- Laser scanning of the 1500 sqm pilot area was conducted using high-precision scanners.
- Point Cloud files were segmented across the engineering team to accelerate modeling.
- PMI developed parametric factory assets, enabling quick and accurate 3D reconstruction.
- Within 140 hours, the entire model—including all client-requested elements—was completed.
Results & Outcome
• The model was submitted along with detailed 2D drawings
• Physical verification by the client confirmed the model’s millimetre-level accuracy
• The project’s success led to PMI being awarded a 50,000 sqm plant-wide as-built conversion project
Conclusion
PMI’s swift execution and digital precision enabled the client to confidently proceed with conveyor planning and plant expansion. What began as a 1500 sqm pilot turned into a large-scale digitization initiative—testament to the value of accurate as-built modeling.