Engineering
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slide127The Interactive Engineering Laboratory is located in the Pardis Innovation Centre and allows the client to view a project in a totally virtual way and three-dimensionally, even before its construction and to carry out in-depth studies and analyses during the design stage. This is possible through the virtual studies, specifically designed for offering the client a preview of the actual plant’s construction.

The Interactive Engineering Laboratory is therefore a useful tool that the engineering team can use when going over the plant’s plans with clients and suppliers, but it is also a space that is available for training newly appointed employees.

slide130One of Geico’s competitive advantages is their commitment to creating new solutions capable of  rising to the ongoing challenges set by innovation.

The main software and tools at the disposal of Geico’s team of highly qualified, specialist engineers includes:

Flow simulations

Geico uses the most advanced software packages to perform simulations of the flow of bodies inside a paint plant, allowing the cycle times, the timescales for the different parts of the plant and the critical points of the production flow to be assessed, allowing the simplest, most economic and efficient layout solution to be identified.

Thanks also to the simulations it is possible to check the correctness of the throughput  of the plants and the sizes of the areas dedicated to the selection of bodies by colours, reducing significantly the paint colour changes inside the booth and the costs associated with this.

Thermal fluid dynamic simulations

The thermal fluid dynamic software makes it possible to verify and optimise the selected engineering solutions, improving the operational quality of the process and its achievement; in this way it is possible to identify the optimal designs and the best pathways that will reduce load losses and noise caused by the movement of fluids such as air or water.

The simulations may also be used to verify the correctness of the circulation in the treatment tanks and its effects on the body, simulating the dipping into the bath process to optimise the expulsion of the air from the piece to be processed phase; the correctness and uniformity of the temperature distribution over the body during the baking phase or to verify the temperature gradients on those parts of the plant involved in the process; the structural behaviour of the body during the process of dipping into the tanks.

4 D

4D is a software that Geico has created for viewing the different installation phases by means of a 3 dimensional model, at the same time as viewing the assembly planning.

The 4D can be viewed in the state-of-the-art IEL (Interactive Engineering Laboratory): during the screening of the plant in 3D it is possible to link the different parts of the drawing to the planning and assembly activities. By analysing the planning and simulating the passage of time, it is possible to visualise, in 3D, the different part of the plant as they take shape or as they are removed from the model (depending on whether this is a question of assembly or dismantling activities) in the sequence defined by planning.

In the 4D simulation it is also possible to, in addition to viewing the sequence of the assembly phases, highlight which parts are missing or have been delayed with respect to the original planning.

The tool is particularly useful both for verifying the complex assembly sequences, highlighting the installation priorities, and for analysing the work in several phases, with dismantling and assembly operations that alternate and overlap each other.

Laser Scanning

Recreating the model of a particular area in 3D by scanning may prove particularly useful for carrying out measurements or undertaking planning activities directly on the relief model itself, above all when it is necessary to carry out work on existing plants.

The laser scanner can be viewed, worked on and adjusted in the Interactive Engineering Laboratory (IEL)

slide1302This is a software package developed by Geico for the client for replacing traditional paper documentation and simplifying the methods used for consulting all the information relating to the plant that is to be maintained.

By reading the Plant Breakdown Structure, the process tags (such as, for example, the trade code, the technical data, spare parts, the routine maintenance records and the reference design and layout diagram) and P&I, the software makes it easy to obtain all the information about the different parts of the plant and/or the equipment on site.

In the case of servicing and maintenance, explanatory videos are available that will assist operators in carrying out their work. J-Doc also has a Pop-Up alert function for organising preventative maintenance operations.

Key information relating to a specific piece of equipment in a plant can be read by using the barcode reader – which is included with the package – to scan the barcode on the equipment itself.

slide1330This piece of software allows the paint plant’s energy consumption levels to be analysed and the identification of the most suitable mix of alternative renewable energy sources available for a particular plant at a given production site.

Beginning with the plant’s production data (capacity, energy consumption levels, shifts and work hours) and on the basis of alternative energy sources present in the different territorial areas in which the plant is to be installed, the software allows different scenarios to be simulated with different mixes of energy produced, or recovered, so as to identify the best technical and financial solutions which will optimise the energy produced from local renewable source with that required by the plant.

slide129The Pardis division carries out energy audits in existing paintshops.

The purpose of the energy audits is to classify the paintshop terms of energy, compare it with the ‘state-of-the-art’ paintshop operating under similar production and weather conditions, assess the improvements that can be achieved in terms of plant engineering and organisation, simulate consumption after the possible intervention and propose further detailed improvements.

Energy classification

A detailed analysis of the plant, consumption per zone, production conditions, energy sources and weather conditions allow the paintshop to be characterised in terms kWh/body produced and liquid and solid waste materials and water consumption. A special classification, which we have called EII (Energy Impact Index), allows a better understanding of the actual scale it has attained. This is useful for understanding what scales of improvement are truly possible.

Simulations and analyses 

We have simulation software packages that are preset for determining consumption rates under different weather conditions, based on the applicable approach. The payback of the possible interventions can also be estimated.

Retrofits

Based on an analysis of the existing situation, a comparison with the actual state-of-the-art condition, from the simulation of the benefits and payback of possible interventions, and an evaluation of the feasibility and of the costs of changing, we are capable of putting together a proposal concerning the retrofitting of existing plants, in order to improve the current classification in terms of eco-sustainability.