Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solutionGet your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solutionGet your solutionGet your solution

TubeShop Consulting ServicesTubeShop Consulting Services Planning and Execution

of an automated pipe shop with software support

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

Work StepsWork Steps

General approach to tube shop consulting projects:

Impressions of the tube shop and work processes

Commissioning of design, software development, machine manufacture and assembly

Machines, layout, software

Identification of problems, requirements

April 2012 3

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

ObservationObservation

Visit to the tube shop

Discussion with involved personnel

How are the drawings / geometries created?

How are the workers and the workflow organized?

What materials and diameters are used?

How does the material get from storage to the machines?

What machines and techniques are used?

April 2012 4

Observation process

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

AnalysisAnalysis

What is the current output and the projected output?

What problems exist in the workshop and on the administrative side?

What capacities exist at the moment and what are required?

What machines / techniques need to be used?

How do current methods need to be adjusted?

What fabrication control system is used?

What budget is available for solutions?

April 2012 5

Analysis process

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

Optimized workshop layout (2D and video)

Workshop

SolutionSolution

Streamlined and coordinated flow of material

Machine recommendations

Detailed outline of cost/benefits

Control of workshop and fabrication processes

April 2012 6

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SolutionSolution

Administrative

Integrated software framework

Generation of CNC data for all integrated machines

Creation of balanced work packages, making optimal use of capacities

Data-transfer from construction to workshop

Automated report functions

Complete overview of the fabrication status of each spool

April 2012 7

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SolutionSolution

Administrative

April 2012 7

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

ExecutionExecution

Commissioning of design and technical drawings

Purchase of machines

Manufacture of storage / transport system components

Assembly of machines and storage / transport system

Installation of an integrated software framework, incl. Operator training

Automatic data-transfer from construction to workshop

Automated report functions

Complete overview of the fabrication status of each spool

April 2012 8

Project Execution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

ExampleExample

Drawings need to be split into spools for fabrication, based on internal parameters

CNC data for machines has to be calculated and prepared

Worksheets and part lists need to be created

Spool data has to be collated into work packages for the workshop

Work orders need to be assigned based on scheduling, material availability, manpower and machine capacities

Operators have to manually enter data into machines

Workshop personnel have to manually create status reports / documentation

Manual Data Preparation / Fabrication

April 2012 9

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

ExampleExample

Drawings are automatically split into spools using consistent logic (from the 3D system used in construction or customizable parameters)

Worksheets, Bills of Material and other documentation is created automatically

Work packages are created automatically, based on capacitices, scheduling, material

All CNC data are automatically generated, operators only need to confirm and start the machine

The fabrication status for every spool is automatically updated and accessible

Automatic Data Preparation / Fabrication

April 2012 9

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

InvestmentInvestment

Example for investment involved in optimizing a tube-shop projected to fabricate 20 projects p.a.:

April 2012 19

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Administrative side:

Tasks can be performed in significantly less time, allowing fewer engineers to perform the job

Constant status updates facilitate change management

All reports can be created automatically

April 2012 20

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Workshop side:

It will be possible to reallocate approx. half the current workshop staff to other jobs (assembly, hull welding, ec.)

Due to bending machines / flame-cutting, fewer t-branches, reducers and elbows will be needed

Automatic welding machines for fittings (flanges, reducers, elbows, t-branches)

Consistent fabrication quality facilitates testing and quality control

Increased workplace safety, reducing risk of accidents

April 2012 20

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

P1

P2

P3

P4

P1

P2

P3

P4

57,6°

57,6°

1000

367

578

685

1100

xyz

Diameter : 4“ XS Transport time : 20 minutes Cutting time : 3x09 min: 27 minutes Elbow assembly : 2*22 min: 44 minutes Elbow grinding time: 4*08 min: 32 minutes Elbow welding time : 4*22 min: 88 minutes Cut bow 57° : 2*10 min: 20 minutes Flange assembly : 2*09 min: 18 minutes Flange welding time: 2*20 min: 40 minutes Flange grinding time: 2*08 min: 16 minutes

Total: 305 minutes

Example for manual fabrication I:

April 2012 10

ExampleExample

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Diameter : 4“ XS Transport time : 3 minutes Cutting time : 4 minutes Bending time : 10 minutes Auto-flange-welding: 7 minutes Flange grinding time: 2*8 min: 16 minutes

Total: 40 minutes

Estimated savings: 265 minutes (approx. 86%)

Example for automized Fabrication I:

April 2012 11

ExampleExample

P1

P2

P3

P4

P1

P2

P3

P4

57,6°

57,6°

1000

367

578

685

1100

xyz

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

P1

P2

P3

P4

P5

P6

P1

P2

P3

P4

P5

P6

90,0°

59,0°

31,0°

1200

900

500

300

583

427

527

146

xyz

Diameter : 6“ XS Transport time : 20 minutes Cutting time 6“ : 4x15 min: 60 minutes Cutting time 4“ : 1x09 min: 9 minutes Elbow assembly : 3*28 min: 84 minutes Elbow grinding time : 6*14 min: 84 minutes Elbow welding time : 6*40 min: 240 minutes Cut bow 31°/59° : 2*15 min: 30 minutes Flange assembly : 6“ 12 minutes Flange assembly : 4“ 9 minutes Flange welding : 30+20 : 50 minutes Flange grinding time: 14+8 min: 22 minutes Assembly & welding reducer : 25+14+

8+40+30 : 117 minutes

Total: 737 minutes

Example for manual Fabrication II:

April 2012 12

ExampleExample

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Diameter : 6“ XS : Transport time : 3 minutes Cutting time : 4+5 min : 9 minutes Bending time : 10 minutes Auto-flange-welding : 6“ : 18 minutes Auto-flange-welding : 4“ : 7 minutes Flange-grinding-time: 14+8 min : 22 minutes Assembly & welding reducer : 25+40+30: 95 minutes

Total: 164 minutes

Estimated savings: 537 minutes (approx. 73 %)

Example for automated Fabrication II:

April 2012 13

ExampleExample

P1

P2

P3

P4

P5

P6

P1

P2

P3

P4

P5

P6

90,0°

59,0°

31,0°

1200

900

500

300

583

427

527

146

xyz

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

P1

P2

P1

P2

6000

xyz

Diameter : 16“ STD Transport time : 20 minutes Cutting time : 31 minutes Flange assembly: 2*20 : 40 minutes Flange welding : 2*(20+20): 80 minutes (semi-auto)

Total: 171 minutes

Example for manual Fabrication III:

April 2012 14

ExampleExample

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Diameter: 16“ STD Transport time: 4 minutes Cutting time: 12 minutes Auto-flange-welding: (both) 43 minutes

Total: 59 minutes

Estimated savings: 112 minutes (approx. 66 %)

Example for automated Fabrication III:

April 2012 15

ExampleExample

P1

P2

P1

P2

6000

xyz

Get your solutionGet your solution

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Manual / Automatic Data Preparation / Fabrication

Avg. 5 spools / drawing Avg. 2000 drawings / project 20 project p.a. Drawings are split into logical spools, spool data is documented (Bills of Material, work

sheets, etc.), balanced work packages are created based on capacities and schedule.

ExampleExample

April 2012 16

Actual savings may differ, based on project details

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Administrative:

Assuming a constant amount of drawings / project, and average costs of 25 € per man-hour, at 20 projects savings of approx. 850,000 € could be feasible:

-Spool splitting is consistent and logical

-All bills of material and order forms are created automatically

-All reports are generated automatically

-All CNC data are generated and automatically transferred to the machines

-All work packages are created based automatically, making the best use of machine capacities and reducing scrap and retooling times

April 2012 20

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Bending:

Internal investigation by the customer has estimated a savings of approx. 100,000 € per project. just by using bending machines (includes cutting and grinding). Assuming a slightly lower ratio of bending (60%), it should still be possible to achieve savings of 90,000 € per project, or almost 1.8 Million € p.a.

April 2012 20

Calculation of savings due to bending machines

Number of Elbows (1 project) 5,918 elbows

60% bending 3,550 bends

Number of saved elbows (1 project) 1,368 elbows

Number of saved elbows (20 projects) 27,360 elbows

Average cost / elbow 15 €

Savings (parts) 410,400 €

Number of saved welds (1 project) 2,736 welds

Number of saved welds (20 projects) 54,720 welds

Welding costs (avg. 2hrs / elbow) 13 € /hr

Savings (welding) 1,422,720 €

Total savings (20 projects) 1,833,120 €

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Welding / Flame-cutting:

April 2012 20

Calculation of savings due to welding and flame-cutting machine

Consumption of reducers 2011 (excluding subcontractors)

Approx. 5,000 pieces

Estimated consumption of reducers (20 projects) Approx. 6,250 pieces

Consumption of tees 2011 (excluding subcontractors)

Approx. 5,600 pieces

Estimated consumption of tees (20 projects) Approx. 7,000 pieces

Total Number of welds (2 / reducer, 3 / tee) 33,500 welds

Welding time (avg. 2hrs, incl. cutting / grinding / fitting )

67,000 hours

Total costs 871,000 €

Calculation of savings due to welding and flame-cutting machine

50% reduction in tees due to flame-cutting - 14,000 hours ( 7,000 welds)

40% reduction in welding time per reducer - 10,000 hours

30% reduction in welding time per remaining tee - 6,300 hours

Total reduction in welding time: 30,300 hours

Savings: 393,300 €

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

SavingsSavings

Savings potential:

Operating costs:

-Utilities (electricity, water, sewage)

-Consumables (welding gases, pressurized air, shot-blasting material)

-Hardware, software installation, operator training

-Total operating costs: approx. 250,000 € p.a.

April 2012 20

Task Savings per Project

Per year (20 Projects p.a.)

Data preparation 42,500 € 825,000 €

Bending 90,000 € 1,800,000 €

Welding (reducers and tees) 19,665 € 393,300 €

Operating costs 250,000 €

Estimated savings 3, 018,300 €

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

AmortizationAmortization

Amortization of Investment over time – 20 projects p.a.

Profit

X-axis Time

April 2012 21

Amortization of Investment over time – 15 projects p.a.Amortization of Investment over time – 10 projects p.a.

Work Steps

Solution

Analysis

Execution

Observation

Investment

Savings

Amortization

Get your solutionGet your solution

3R software solutions - Kleistraße 39 - 59073 Hamm - GermanyPhone +49 2381 9724 710 - Fax +49 2381 9724 711 - Mail info@3-r.de