Draft: Last revision: 7/22/2018 7:44 AM
Executive Overview:
We could automate the IFF process to increase accuracy, ease the workload, and free up people to perform more valuable activities. Current estimates place the man hours required to check model compliance to package is from 18,000 to 22,500 hours annually. Automating the process is possible and could reduce man hours to 3,000 hours annually. Projected savings range from $200,000 to $1,387,500.
Detailed Discussion
Generally the steps involved in checking IFF models for LSP Design compliance are:
A person checks 3D models of the 2D design package. This activity occurs no less than once per line, sometimes two or three times before fabrication approval.
Not every line in the design is modeled.
Every tool model has no less than three lines, perhaps thirty five on average, and many have over seventy five.
Checking that the model is compliant to the package is preformed manually. Two software programs are used. Models are opened and viewed with Navis, packages are viewed with a PDF or DWFx viewer. A person compares the two files visually validating the information matches.
A perfect design to model exercise would be error free and complete requiring on average ten minutes per line to approve.
Rarely is the model error or omission free, requiring two to five separate checks.
People make errors or omissions during the somewhat complex process of manually operating two files on separate computer screens, or while switching back and forth on one screen. Everyone needs training before understand the check and approval process.
The design packages are normally created using AutoCAD and exported to a PDF/DWFx format. The models are created with a few types of software, Revit, AutoCAD Fabrication, Plant, MEP, Cadworx to name some. Models are viewed in Autodesk Navis, packages in Adobe PDF or Autodesk Design review viewer
What both model and package files share is they are both a form of database optimized to be viewed graphically. At their core they are data files.
Autodesk provides tools to access to the data in the form of what is referred to as an Application Program Interface, or API.
Microsoft provides a free version of Visual studio which can be configured to access the data in both package and model files.
Therefore creating a software program to augment the process of validating the model contains the same data as the package is certain.
Amassing all this information produces a hypothesis. A program to open and verify lines in the model match the package is certain. Such a program would not make human error/omission. Software executes much faster than a person. Software would not require two monitors.
What would such a program be worth in reducing the effort to provide valuable mandatory work?
What would this software cost to produce?
How much training would be required to use the software?
How quickly could this software be deployed and active in the current process?
Answers:
Collecting high level preliminary data provides some ideas, some partial answers. Review the conservative figures below, see if you agree with the projections.
|
1 |
Number of Tools |
800 |
|
2 |
Lines per tool |
35 |
|
3 |
Mins to check a line |
10 |
|
4 |
Number of chks to IFF |
2 |
|
5 |
Manhour value |
$ 45.00 |
|
6 |
Sub Total |
$ 420,000 |
|
7 |
Software chk time (mins) |
3 |
|
8 |
Manhour value (operator) |
$ 45.00 |
|
9 |
Subtotal |
$ 126,000 |
|
|
||
|
10 |
Delta/Difference |
$ 294,000 |
|
|
||
|
11 |
Estimated Development Cost |
$ 50,000 |
|
|
||
|
12 |
Net Value |
$ 244,000 |
Explanations:
1 Amount of tools that will be modeled and checked for IFF
2 Lines per tool that will be checked against the package
3 How many minutes does it take a person to complete the check in the manner they currently use, comparing two files against each other manually.
4 On average how many time will the line be checked before it’s approved for IFF?
5 How much is the person preforming the work billing the owner?
6 Value associated with the task of people checking models against packages for IFF
7 Number of minutes same work of comparing model to package is estimated to take.
8 Same as #5 above.
9 Same as #6 above using software program
10 Software process vs manual process cost difference.
11 Projection of cost to product software program
12 Bottom line projected value to make process better.
.
.
On the other hand review the optimistic figures below, see if you agree with these projections.
|
1 |
Number of Tools |
1000 |
|
2 |
Lines per tool |
50 |
|
3 |
Mins to check a line |
15 |
|
4 |
Number of chks to IFF |
2 |
|
5 |
Manhour value |
$ 75.00 |
|
6 |
Sub Total |
$ 1,875,000 |
|
7 |
Software chk time (mins) |
2 |
|
8 |
Manhour value (operator) |
$ 75.00 |
|
9 |
Subtotal |
$ 250,000 |
|
|
||
|
10 |
Delta/Difference |
$ 1,625,000 |
|
|
||
|
11 |
Estimated Development Cost |
$ 75,000 |
|
|
||
|
12 |
Net Value |
$ 1,550,000 |
Hopefully we can view a minimal value is the conservative view of $244,000. Real value would emerge with better metrics, homework, and investigation.