3D Virtual Foundry Modeling and Analysis in E-Factory CAD.

E-factory CAD is a tool that enables visual 3D factory molding, planning and analysis of it in the virtual
environment. It can be used for the existing plants as well as for planning of new shop floor layout. It has
three modules namely, Factory CAD, Factory Plan, and Factory Flow for complete definition of the factory
and to analyze different strategies to cut down the lead time and cost. 3D factory Cad model can be
represented by various objects (example, conveyor, material handling equipments, operators, overhead
conveyor etc.) that are made available in the software tool. In addition, a facility for customization and
definition of other objects is also available for complete definition of the factory 3D CAD model for its
further analysis. Factory planning module helps the designer in understanding different layouts and their
relationship, allow planning of space requirement and a lot more. The virtually build factory can be
analyzed for optimum material flow, parts storage, travel distance & cost, labor time, etc by using a module
called Factory Flow.

I have worked on the E-FACTORY CAD (V 9.0) software in our CAD/CAM lab. With the understanding of
this tool a simple case study of 'virtual foundry modeling and analysis' was carried to get more insight of
the software. Figure 1 depicts foundry 2D model in E-Factory CAD. For 3D modeling of a foundry
(Figure 2 and 3), initially we have to open the AutoCAD environment within the E-factory CAD and then
set factory drawing parameters (units, Program layer file, Line type etc.). This is followed by, drawing of
floor area, preparation of column & grids, selection and installation of required machines (from available
objects) with the help of block managers. Block manager also facilitates use of operator, vehicle,
equipment, etc. Mezzanine module is used to model multiple floors, if required. Finally, we have to put the
guardrail around the machine to avoid collision between other factory objects. Add suitable conveyor to the
current factory model to complete the 3D factory CAD model. The 3D foundry model developed in this
work by using E-factory CAD software is shown in figure 3. We can also export the file of this virtual
foundry model to WMF (for project management), DXF (visualization in CAD modelers), VRML (Figure
4 - visualization in web-browser), and JT (visualization in PLM Team center), etc. for various factory
design and analysis applications.

Factory PLAN: After modeling of a factory we have to decide whether the layout is feasible or not by
using Factory Plan tool. It provides introductory level solution for designing the layout of production floors
to offices to laboratories. Initially, we have to open the Factory plan within the Auto CAD environment.
This is followed by giving the factory plan data files i.e. AMX (Relationship of activities), SPACE (height
& width ratios of activity), SPACE STD (space type & their color, layer etc.), REASON CODES (for
defining the proximity relationship). After this, we have to provide activity or department list and define
the space information of an activity along with the proximity relationship between these activities. This will
enable to obtain the score for choosing the best alternative layout as shown in figure (5). Score is also used
to specify cutoff points for layout quality assessment. Here SLP (Systemic layout planning) method is used
for factory planning. It is a generalized approach to layout developed by Richard Muther that utilizes a grid
matrix to display ratings of the relative importance of the distance between departments. The Figure 6
shows the relationship chart with material flow in which importance rating are indicated by code letters (a,
e, i, o, u, x & z) in the matrix & range from (a) absolutely necessary (b) Z-very undesirable. Figure 5 gives
a screen print for the planning a factory with Score. Similarly, Figure 6 shows the modeling the
relationship for material flow.
Factory Flow: It is an optimization module in E-factory CAD. Factory layouts can be analyzed by using
production history, part routing information, material handling and storage requirement, material handling
equipment specification etc. Virtual factory model can be analyzed for alternative material flow and this
evaluating will help to improve the Production efficiency.

Flow analysis can be carried out by opening the factory flow within Auto CAD environment and then
drawing the process flow diagram (or gives the PRD, MHE, PARTS file as input for the data migration) for
the plant into assembly data followed by importing the work center list from the drawing and finally giving
the material handling equipment data i.e. Fixed cost, Avg. speed, quantity used etc. Running a factory flow
module helps to optimize the factory layout based on material flow distances, frequency and cost. This
helps in reducing material handling and improving the outputs and hence the productivity of the factory.
Figure 7 depicts the material handling utilization in which it gives name of material handling equipment;
quantity used, busy per minute, available minutes per year and utilization. Figure 8 shows Activity time
report in which it gives product name, Activity name i.e. Load or unload activity, Activity scope i.e. per
trip, and Activity time in minute. Figure 9 shows the exported Excel report. Figure 10 depicts the material
flow path i.e. how material is moving from one work center to another that can be generated during the
analysis of a layout.

Figure 1: Foundry 2D model in E-factory CAD Figure 2: Foundry 3D model in E-factory CAD

Figure 3: Foundry model Figure 4: Foundry VRML model for Cosmo Player
 Figure 5: Factory Plan with SCORE Figure 6: Relationship chart with material flow

Figure 7: Material handling utilization Figure 8: Activity time report.

Figure 9: Excel Report Figure10: shows the material flow path